Aerosol separator; and method

ABSTRACT

Crankcase ventilation arrangements are shown. Preferred wet laid media materials, for use in such arrangements are described. Also described and shown are example crankcase ventilation components, parts for use with a preferred media described and characterized.

This application is a continuation of U.S. application Ser. No.11/883,690, filed Apr. 4, 2008, which will issue on May 15, 2012 as U.S.Pat. No. 8,177,875, and which is a U.S. National Stage Application ofInternational Application Number PCT/US2006/004639, filed on Jan. 31,2006, and claims priority to U.S. Provisional Application Ser. No.60/650,051, filed Feb. 4, 2005.

This application incorporates the following U.S. Patents herein byreference: U.S. Pat. No. 5,853,439; U.S. Pat. No. 6,171,355; U.S. Pat.No. 6,355,076; U.S. Pat. No. 6,143,049; U.S. Pat. No. 6,187,073; U.S.Pat. No. 6,290,739; U.S. Pat. No. 6,540,801; U.S. Pat. No. 6,530,969.This application incorporates by reference PCT Publication WO 01/47618published on Jul. 5, 2001, and PCT Publication WO 00/32295 published onJun. 8, 2000. This application incorporates by reference commonlyassigned U.S. patent application Ser. No. 10/168,906 filed Jun. 20,2002. This application also incorporates, with edits, portions of U.S.Provisional Application 60/547,759, filed Feb. 23, 2004 and U.S.Provisional Application filed Jan. 11, 2005 entitled Aerosol Separator;and, Methods. U.S. Provisional Application 60/547,759 and U.S.Provisional Application filed Jan. 11, 2005 entitled Aerosol Separator;and, Methods, are incorporated herein by reference.

TECHNICAL FIELD

This disclosure relates to systems and methods for separatinghydrophobic fluids (such as oils) which are entrained as aerosols, fromgas streams (for example crankcase gases). Preferred arrangements alsoprovide for filtration of other fine contaminants, for example carbonmaterial, from the gas streams. Methods for conducting the separationsare also provided.

BACKGROUND

Certain gas streams, such as blow-by gases from the crankcase of dieselengines, carry substantial amounts of entrained oils therein, asaerosol. The majority of the oil droplets within the aerosol aregenerally within the size of 0.1-5.0 microns.

In addition, such gas streams also carry substantial amounts of finecontaminant, such as carbon contaminants. Such contaminants generallyhave an average particle size of about 0.5-3.0 microns. It is preferredto reduce the amount of such contaminants in these systems.

A variety of efforts have been directed to the above types of concerns.The variables toward which improvements are desired generally concernthe following: (a) size/efficiency concerns; that is, a desire for goodefficiency of separation while at the same time avoidance of arequirement for a large separator system; (b) cost/efficiency; that is,a desire for good or high efficiency without the requirement ofsubstantially expensive systems; (c) versatility; that is, developmentof systems that can be adapted for a wide variety of applications anduses, without significant re-engineering; and, (d)cleanability/regeneratability; that is, development of systems which canbe readily cleaned (or regenerated) if such becomes desired, afterprolonged use.

SUMMARY OF THE DISCLOSURE

This disclosure particularly concerns development of preferred crankcaseventilation (CCV) filters. It particularly concerns use of advantageousfilter media, in arrangements to filter crankcase gases. The preferredmedia is provided in sheet form from a wet laid process. It can beincorporated into filter arrangements, in a variety of ways, for exampleby a wrapping or coiling approach or by providing in a panelconstruction.

According to the present disclosure, filter constructions for preferreduses to filter blow-by gases from engine crankcases are provided.Example constructions are provided. Also provided are preferred filterelement or cartridge arrangements including the preferred type of media.Further, methods are provided.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of an engine system using a filterarrangement constructed according to principles of this disclosure;

FIG. 2 is a schematic side elevational view of one embodiment of afilter arrangement, constructed according to principles of thisdisclosure;

FIG. 3 is an end view of the filter arrangement depicted in FIG. 2;

FIG. 4 is a cross-sectional view of the filter arrangement depicted inFIGS. 2 and 3, and taken along the line 4-4 of FIG. 3;

FIG. 5 is a schematic cross-sectional view of one embodiment of a filterelement utilized in the filter arrangement of FIGS. 2-4; thecross-section being the same cross-section taken along the line 4-4, butdepicting the filter element removed from the housing construction;

FIG. 6 is a schematic cross-sectional view of one embodiment of thehousing construction body; the cross-section being analogous to thecross-section taken along the line 4-4, but depicting only the housingconstruction body and with a lid removed;

FIG. 7 is a schematic cross-sectional view of one embodiment of thehousing construction cover member; the cross-section being analogous tothe cross-section taken along the line 4-4, but depicting only thehousing construction cover member;

FIG. 8 is a schematic cross-sectional view of a first alternativeembodiment of a filter element that can be utilized in the filterarrangement of FIGS. 2-4; the cross-section being analogous to thecross-section of FIG. 5;

FIG. 9 is a schematic cross-sectional view of a second alternativeembodiment of a filter element that can be utilized in the filterarrangement of FIGS. 2-4; the cross-section being analogous to thecross-section of FIG. 5;

FIG. 10 is a schematic perspective view of another embodiment of afilter arrangement, constructed according to principles of thisdisclosure;

FIG. 11 is a top plan view of the filter arrangement depicted in FIG.10;

FIG. 12 is a schematic cross-sectional view of the filter arrangementdepicted in FIGS. 10 and 11, and taken along the line 12-12 of FIG. 11;

FIG. 13 is an end view of one embodiment of a filter element utilized inthe filter arrangement of FIGS. 10-12;

FIG. 14 is an opposite end view of the filter element depicted in FIG.13;

FIG. 15 is a schematic cross-sectional view of the filter elementdepicted in FIGS. 13 and 14, the cross section being taken along theline 15-15 of FIG. 13;

FIG. 15A is an enlarged, fragmented, schematic cross-sectional view of aportion of the filter element depicted in FIG. 15;

FIG. 16 is a schematic perspective view of an alternative embodiment ofa pre-formed insert that may be utilized within the filter elementdepicted in FIGS. 13-15;

FIG. 17 is a schematic end view of the pre-formed insert depicted inFIG. 16;

FIG. 18 is a schematic cross-sectional view of the pre-formed insertdepicted in FIGS. 16 and 17, the cross section being taken along theline 18-18 of FIG. 17;

FIG. 19 is an enlarged, schematic cross-sectional view of a portion ofthe pre-formed insert shown in FIG. 18;

FIG. 20 is an enlarged, schematic, cross-sectional view of anotherportion of the pre-formed insert depicted in FIG. 18;

FIG. 21 is a schematic cross-sectional view of another embodiment of afilter element constructed according to principles of this disclosure,and utilizing the pre-formed insert of FIGS. 16-20;

FIG. 22 is a schematic, cross-sectional view of one embodiment of amolding technique for constructing filter elements according to thisdisclosure;

FIG. 23 is a schematic, cross-sectional view of one embodiment of amolding technique for constructing filter elements according to thisdisclosure; and

FIG. 24 is a schematic, cross-sectional view, of an additionalembodiment of a crankcase ventilation filter including a media stageaccording to the present disclosure therein.

DETAILED DESCRIPTION I. A Typical Application—Engine Crankcase BreatherFilter

Pressure-charged diesel engines often generate “blow-by” gases, i.e., aflow of air-fuel mixture leaking past pistons from the combustionchambers. Such “blow-by gases” generally comprise a gas phase, forexample air or combustion off gases, carrying therein: (a) hydrophobicfluid (e.g., oil including fuel aerosol) principally comprising 0.1-5.0micron droplets (principally, by number); and, (b) carbon contaminantfrom combustion, typically comprising carbon particles, a majority ofwhich are about 0.1-10 microns in size. Such “blow-by gases” aregenerally directed outwardly from the engine block, through a blow-byvent.

Herein when the term “hydrophobic” fluids is used in reference to theentrained liquid aerosol in gas flow, reference is meant to nonaqueousfluids, especially oils. Generally such materials are immiscible inwater. Herein the term “gas” or variants thereof, used in connectionwith the carrier fluid, refers to air, combustion off gases, and othercarrier gases for the aerosol.

The gases may carry substantial amounts of other components. Suchcomponents may include, for example, copper, lead, silicone, aluminum,iron, chromium, sodium, molybdenum, tin, and other heavy metals.

Engines operating in such systems as trucks, farm machinery, boats,buses, and other systems generally comprising diesel engines, may havesignificant gas flows contaminated as described above. For example, flowrates and volumes on the order of 2-50 cubic feet per minute (cfm),typically 5 to 10 cfm, are fairly common.

FIG. 1 illustrates a schematic indicating a typical system 28 in which acoalescer/separator arrangement according to the present invention wouldbe utilized. Referring to FIG. 1, block 30 represents a turbochargeddiesel engine. Air is taken to the engine 30 through an air filter 32.Air filter or cleaner 32 cleans the air taken in from the atmosphere. Aturbo 34 draws the clean air from the air filter 32 and pushes it intoengine 30. While in engine 30, the air undergoes compression andcombustion by engaging with pistons and fuel. During the combustionprocess, the engine 30 gives off blow-by gases. A filter arrangement 36is in gas flow communication with engine 30 and cleans the blow-bygases. From filter arrangement 36, the air is directed through channel38 and through a pressure valve 40. From there, the air is again pulledthrough by the turbo 34 and into the engine 30. Regulator valve orpressure valve 40 regulates the amount of pressure in the enginecrankcase 30. Pressure valve 40 opens more and more, as the pressure inthe engine crankcase increases, in order to try to decrease the pressureto an optimal level. The pressure valve 40 closes to a smaller amountwhen it is desirable to increase the pressure within the engine. A checkvalve 42 is provided, such that when the pressure exceeds a certainamount in the engine crankcase 30, the check valve 42 opens to theatmosphere, to prevent engine damage.

According to this disclosure, the filter arrangement 36 for separating ahydrophobic liquid phase from a gaseous stream (sometimes referred toherein as a coalescer/separator arrangement) is provided. In operation,a contaminated gas flow is directed into the coalescer/separatorarrangement 36. Within the arrangement 36, the fine oil phase or aerosolphase (i.e., hydrophobic phase) coalesces. The arrangement 36 isconstructed so that as the hydrophobic phase coalesces into droplets, itwill drain as a liquid such that it can readily be collected and removedfrom the system. With preferred arrangements as described herein below,the coalescer or coalescer/separator, especially with the oil phase inpart loaded thereon, operates as a filter for other contaminant (such ascarbon contaminant) carried in the gas stream. Indeed, in some systems,as the oil is drained from the system, it will provide someself-cleaning of the coalescer because the oil will carry therein aportion of the trapped carbon contaminant.

The principles according to the present disclosure can be implemented insingle stage arrangements or multistage arrangements. In many of thefigures, multistage arrangements are depicted. In the generaldescriptions, we will explain how the arrangements could be varied to asingle stage arrangement, if desired.

II. Multi-Stage Oil Aerosol Separator Embodiment, FIGS. 2-9

Referring to FIG. 2, an embodiment of a crankcase gas filter or filterarrangement 36 is depicted at reference numeral 50. The typical filterarrangement 50 depicted includes a housing 52. The depicted housing 52has a two-piece construction. More specifically, housing 52 comprises abody assembly 54 and a removable cover member 56. The body assembly 54includes body 55 and lid 57.

Referring to FIGS. 2 and 4, the housing 52 depicted includes thefollowing three (3) ports: gas flow inlet port 58; gas flow outlet port60; and liquid flow outlet port or liquid drain 62.

In general, the filter arrangement 50 may be generally referenced hereinas a “multi-stage” arrangement because it includes both: (a) apreliminary coalescer filter, to remove a liquid phase from a liquidentrained gas stream; and, (b) at least a single but could includemultiple, downstream or second stage filters, for further purificationof the air stream. In FIG. 4, a cross-sectional view of the filterarrangement 50 including both the housing 52 and its internal componentsis depicted. In general, the filter arrangement 50 includes an optionalfirst stage coalescer filter 64, and a second stage tubular constructionof filter media 66.

In some arrangements, first stage coalescer filter 64 could be left out,with only the filter media section 66 used. In such arrangements, thefilter media section 66 could be used for both coalescing and drainageas well as particular filtering. Media appropriate for this is describedin detail below.

In use, an air or gas stream to be modified is directed through theinlet port 58, and through the optional first stage coalescer filter 64.At least a portion of the liquid phase is coalesced and removed from thegaseous stream by the optional first stage coalescer filter 64. Theliquid that is coalesced within the first stage coalescer filter 64drains by gravity, and in the particular embodiment shown exits thehousing 52 through the liquid flow outlet port 62. The gas phase isdirected through media construction 66. The media construction 66removes at least a portion of particulates from the gas stream andprovides for further coalescing and drainage of entrained liquids. Thecleaned gas stream is then directed outwardly from the housing 52through the gas flow outlet 60.

As can be seen in FIG. 5, in the embodiment shown the (optional) firststage coalescer filter 64 and the tubular construction of media 66 are asingle, unitary construction forming a filter arrangement or element 70.In the preferred embodiment illustrated, the filter element 70 isremovable and replaceable with respect to the housing 52. That is, it isa serviceable filter cartridge or element. By “unitary” in this contextit is meant that the optional first stage coalescer filter 64 and thetubular construction of media 66 cannot be separated from one anotherwithout destroying a portion of the assembled element 70. In certainembodiments, end caps 202, 254 form part of the unitary construction.

In reference again to FIG. 4, for the housing 52 depicted, there is aninlet tube construction 72, a regulator valve housing 74, a canisterportion 76, and a outlet tube construction 78. In the embodiment shown,each of the inlet tube construction 72, regulator valve housing 74,canister portion 76, and outlet tube construction 78 form a portion ofthe body 55. Together with the lid 57, the body 55 and lid 57 are partof the body assembly 54.

In the one shown, the inlet tube construction 72 is a cylindrical member80 that defines the gas flow inlet port 58. In certain assemblies, theinlet tube construction 78 is in gas flow communication with thecrankcase of engine 30, in order to treat blow-by gases emitted from thecrankcase.

The regulator valve housing 74 depicted is immediately downstream of theinlet tube construction 72. The regulator valve housing 74 includes anouter surrounding wall 82 defining an open interior 84, where the gas tobe treated is allowed to flow and collect before passing into the filterelement 70. The regulator valve housing 74 also includes an internalwall 86 forming a neck 88. In the one illustrated, the regulator valvehousing 74 also includes a shelf 90 for holding and supporting the lid57 thereon. The neck 88 holds and supports a regulator valve assembly 92(FIG. 4) between the canister portion 76 and the lid 57.

In reference to FIG. 4, the valve assembly 92 is constructed andarranged to regulate the gas flow from the crankcase of the engine 30and through the filter element 70. While a variety of valveconstructions are contemplated herein, the particular valve assembly 92depicted includes diaphragm construction 94 and a biasing mechanism,such as spring 96. In FIG. 4, note that the diaphragm construction 94 isgenerally circular with an outermost rim 98 that is held by and restsupon shelf 90. The diaphragm construction 94 also includes a groove 100having a generally U-shaped cross-section and being generally circular,in plan view. The groove 100 is inboard of the rim 98. The groove 100helps to keep the diaphragm construction 94 properly oriented andcentered upon the neck 88. Secured to the diaphragm construction 94 is acentering projection 102. The centering projection 102 is sized toextend into the interior portion 104 of the neck 88. In the one shown,the centering projection 102 is secured to the diaphragm construction 94in a region inboard of the groove 100. The centering projection 102,together with the groove 100, helps to keep the diaphragm construction94 properly oriented over the neck 88.

Still in reference to FIG. 4, in the particular valve assembly 92 shown,the spring 96 rests around the outside wall 86 of the neck 88. Thespring 96 applies a force to the diaphragm construction 94 to pull thediaphragm construction 94 in a direction toward the neck 88 and towardthe filter element 70. Note that there is a gap 106 between thediaphragm construction 94 and the neck 88. The gap 106 allows for gasflow from the interior 84 of the regulator valve housing 74 and into theinterior portion 104 of the neck 88.

In operation, the valve assembly 92 generally operates to limit the rateof gas flow from the engine crankcase 30 to the filter element 70. Thespring 96 pulls the diaphragm construction 94 toward the neck 88 againstthe pressure exerted by the gas flow inwardly from the gas flow inlet58. The diaphragm construction 94 is constructed of a flexible material,such as rubber. As such, a diaphragm construction 94 is allowed to flexin a direction away from the neck 88 and toward the lid 57 in the volume108 defined between the lid 57 and the shelf 90 of the regulator valvehousing 74.

In reference now to FIG. 6, the canister portion 76 of the body 55includes an outer surrounding wall 110 that is generally tubular inconstruction to define an open interior 112 for receipt of the filterelement 70. In the one depicted, the wall 110 generally is cylindricalto define a circular cross-section. The canister 76 includes an end wall114 that helps to hold and contain the filter element 70 inside of thecanister 76. The end wall 114 includes a projection 116 extending from aflat, planar portion 118. When the filter element 70 is operablyassembled within the housing 52, the projection 116 will act as asecondary, or supplemental sealing mechanism to create a secondary seal120 (FIG. 4) between the end wall 114 of the body 55 and the element 70.The primary sealing function is in a radial sealing system between thefilter element 70 and the housing 52, which is described in furtherdetail below. The secondary seal 120 helps to prevent unintended amountsof oil seepage from passing along the end wall 114 between the filterelement 70 and the housing 52. It is noted that in alternatearrangements axial seals between the filter element and the housing canbe used, with radial seals avoided.

Still in reference to FIG. 6, note that the body 55 includes a firsttubular region 122 having a first greatest outer dimension and a secondtubular region 124 having a second greatest outer dimension. In theparticular example illustrated, the greatest outer dimensions of thetubular region 122 and tubular region 124 are diameters. The diameter ofthe tubular region 122 is greater than the diameter of the tubularregion 124, to create a stepped region 126 therebetween. The tubularregion 124 defines an inner, annular sealing surface 128. As will bedescribed further below, the sealing surface creates a surface of whichit can accept pressure of a seal member to create a radial sealtherebetween. The tubular region 122 is spaced from the filter element70, when the filter element 70 is operably assembled therein, to createa gas flow volume 130 therebetween.

As can be seen in FIG. 2, the body assembly 54 and the cover member 56are joined to one another along a seam 132 by a latch arrangement 134.The latch arrangement 134 includes a plurality of latches 136 that areused to securely hold the cover member 56 and body assembly 54 togetheralong the seam 132. The latches 136 allow the cover member 56 to beselectively removed from the body assembly 54 in order to accessinternal components, such as filter element 70 during servicing. Therecan be a number of latches, and in the particular embodimentillustrated, there are three latches 136. As can be seen in FIGS. 2, 4,and 6, the body 55 includes a latch mount 138 thereon for each of thelatches 136. In FIG. 2, it can be seen that the cover member 56 includesappropriate latch receiving structure, such as a slot 140, for receivinga hook portion 142 of each of the latches 136.

The body 55 has an open end 144 (FIG. 6) that is opposite of the endwall 114, in the illustrated embodiment. The open end 144 iscircumscribed by a rim 146 that is for communicating with a receivingslot 148 (FIG. 7) in the cover member 56.

Turning now to the cover member 56 illustrated in FIG. 7, note that thecover member 56 has a bowl or funnel-shaped end second 150. Thecombination of bowl 150 and drain 62 comprises a liquid collectionarrangement 152. In use, as liquid coalesces within the housing 52, itwill drain downwardly toward the bowl 150 and will be funneled to thedrain 62. Typically, appropriate drain lines will be secured to thedrain 62 to direct the collected liquid as desired, for example, to anoil sump.

In reference to FIG. 7, still further detail of the illustrated covermember 56 is shown. In the particular embodiment illustrated, in thecover member 56 includes and outer surrounding wall 154 and an innerwall 156 spaced from the outer wall 154. The outer wall 154 and theinner wall 156 together define the slot 148. The slot 148 functions as avolume 158 for receipt of the body assembly 54, in particular, the rim146. The outer surrounding wall 154 also includes the latch receivingstructure 140.

The volume 158 also provides a seat 160 for holding and containing agasket member such as O-ring 162 (FIG. 4). In the construction shown,the O-ring 162 is between the rim 146 and the seat 160. The latcharrangement 154 provides axial forces to squeeze the cover member 56 andbody assembly 54 together. This provides a force of the rim 146 on theO-ring 162 to create a seal 164 (FIG. 4) between the cover member 56 andbody assembly 54. This seal 164 prevents unintended amounts of gas flowto flow between the body assembly 54 and the cover member 56. Rather,the seal 164 forces the gas flow to exit through the gas flow outlet 60.

In reference again to FIG. 7, the inner wall 156 provides an annular,sealing surface 166. The annular sealing surface 166 provides astructure against which a sealing portion of the filter element 70 isoriented to create a radial seal therewith. This is described in furtherdetail below.

The cover member 56 also includes an end wall 168 that is generallynormal to the inner wall 156. The end wall 168 acts as a stop 170 fororientation of the filter element 70. In other words, the stop 170prevents the filter element 70 from moving axially within the housing52. Extending from the end wall 168 is a projection 172. When filterelement 70 is operably installed within housing 52, the projection 172will be pressed against a sealing portion of the filter element 70 tocreate a secondary seal 174 (FIG. 4) with the filter element 70. Thesecondary seal 174 will help to prevent unintended amounts of oilseepage from traveling from within the filter element 70 to the volume130 outside of the filter element 70. Again, the primary sealingfunction is accomplished by a radial sealing system, to be describedfurther below. Also, again, many of the techniques described herein canbe applied in arrangements in which the primary sealing function isprovided by axial seals.

Extending from the end wall 168 is a sloped wall 176 that terminates inthe liquid flow outlet 62. The sloped wall 176 forms the funnel shapedsection or bowl 150.

Note that the liquid flow outlet 62 includes a threaded section 178.Threaded section 178 can be a brass insert, and is convenient forconnecting fittings to lead to an oil sump, for example.

Herein, the term “gas flow direction arrangement” or variants thereofwill sometimes be used to refer to the portions of arrangements thatdirect gas flow. For filter arrangement 50, FIG. 4, this would includethe gas flow inlet 58, the inlet tube construction 72, the various wallsof the housing 52 (including the walls 82, 86, 110, and 154) and theoutlet tube construction 78, including the gas flow outlet 60. The gasflow direction arrangement generally operates to ensure proper gas flow,through the filter element 70 in proper order.

Attention is now directed to FIGS. 4 and 5. The filter element 70 isshown in FIG. 4 operably assembled within the housing 52. By the term“operably assembled” and variants thereof, it is meant that the filterelement 70 is oriented within the housing 52 such that the seals are inplace and gas flow is permitted to flow properly from the inlet 58,through the filter element 70, and out through the outlet 60.

It can be seen in FIGS. 4 and 5 that the filter element 70 includes boththe optional first stage coalescer filter 64 and the tubularconstruction media of 66 in a single construction. When the filterelement 70 is handled, for example during servicing, both the firststage coalescer filter 64 and the tubular construction of media 66 arehandled together. In general, the tubular construction of media 66includes a media pack 190 arranged in a closed, tubular form to definean open filter interior 192. In preferred constructions, the media pack190 will be configured to have a generally cylindrical shape, defining acircular cross section.

The media pack 190 can be many different types of media, adjusted toachieve the desired efficiency and restriction. One example of media 194useable in media pack 190 is formed media. Another example is pleatedmedia. By “pleated media”, it is meant a flexible sheet of media foldedinto a plurality of pleats. Herein below, a preferred media for themedia pack 190 is described, as a wet laid media having preferredcharacteristics. This media is preferred when the function of media pack190 is to provide for both: coalescing/drainage function and aparticulate entrapment function. This function can be provided by mediapack 190 when the media pack 190 is used without the optional firststage coalescer filter 64 or when it is used with the optional firststage coalescer filter 64. It is noted that media pack 190 can beprovided in a multilayer or multistage form.

In the illustrated embodiment, the media 194 has a first end 196 and anopposite, second end 198. The length of the media 194 extends betweenthe first end 196 and second end 198. In the filter element 70 shown, atthe first end 196 is a first end cap arrangement 200. In the particularembodiment shown in FIG. 5, the end cap arrangement 200 includes an endcap 202 and the first stage coalescer filter 64. In certainconstructions, the end cap arrangement 200 is a single, unitarystructure.

In some embodiments, the end cap 202 includes a ring 204 of a molded,polymeric material. The ring 204 defines a center aperture 206 that, inthe preferred embodiment illustrated, is centered in the ring 204. By“centered”, it is meant that the aperture 206 has a center of symmetrythat is the same as the center of symmetry of the ring 204. In otherwords, the center 206 is preferably not eccentrically disposed withinthe ring 204.

In some arrangements, the center aperture 206 will be circular and havea diameter that is not greater than about 50 percent of the diameter ofthe ring 204. In some arrangements, the diameter of the aperture 206will be less than 40 percent of the diameter of the ring 204.

The ring 204 also includes an outer, annular surface 208. When filterelement 70 is operably assembled within housing 52, the outer annularsealing surface 208 functions as a sealing portion 210. In preferredarrangements, the sealing portion 210 includes a stepped construction212.

In particular, the stepped construction 212 helps with the insertion andformation of a radial seal 214 (FIG. 4) between the end-cap arrangement200 and the sealing surface 128 of the housing 52. In FIG. 5, thestepped construction 212 includes a first region of largest diameter216, adjacent to a second region 218 of a diameter smaller than thefirst region 216, adjacent to a third region 220 of a diameter smallerthan that of the second region 218. This stepped construction 212 ofdecreasing diameters, results in a construction that helps with theinsertion of the filter element 70 in the body 55.

The sealing portion 210 of the end cap 202 can be made from acompressible material, such that there is radial compression of thesealing portion 210 against the sealing surface 128, when the element isoperably installed in the housing 52. Example, usable materials for thesealing portion 210, and the entire end cap 202, are described below. Ingeneral, end caps 202 can comprise a soft, polyurethane foam having anas-molded density of typically, less than 22 lbs per cubic foot, forexample about 12-22 lbs. per cubic foot. Of course alternate materialscan be used in variations from the examples described herein, with unitsstill incorporating many of the principles described.

Still in reference to FIG. 5, the end cap arrangement 200 also includesa frame construction 222 oriented in the center aperture 206 of the ring204. The frame construction 222 holds, contains, and encapsulates aregion of fibrous media 224. In the construction shown, the fibrousmedia 224 is used as the optional first stage coalescer filter 64. Incertain arrangements, the fibrous media 224 comprises at least onelayer, and typically, a plurality of layers 226 of nonwoven, nonpleated,non open tubular, coalescing media. In the embodiment shown in FIG. 5,there are two layers 226, 228 of fibrous media 224. Certain usable,example materials for the fibrous media 224 are described further below.Again, it is noted that in some arrangements the first stage coalescerfilter 64 is not used, and only the tubular filter construction 66 ispresent.

Still in reference to FIG. 5, in the frame construction 220 depicted,the frame construction 222 is a multi-piece, in particular, a two-piececonstruction including a first frame piece 230 and a second frame piece232. The first frame piece 230 includes a support grid 234 in coveringrelation to the upstream face 236 of the fibrous media 224. The supportgrid 234 is a porous, mesh that permits gas flow to flow therethroughand across the fibrous media 224. The support grid 234 providesstructural support to the fibrous media 224.

Similarly, the second frame piece 232 includes a porous support grid 238in covering relation to the downstream face 240 of the fibrous media224. The support grid 238 also provides structural support for thefibrous media 224, while permitting gas flow to penetrate therethroughand into the open filter interior 192.

In the arrangement shown, the first frame piece 230 and the second framepiece 232 are arranged adjacent to each other to form a retaining pocket242 between the support grid 234 and support grid 238 that holds orencapsulates the fibrous media 224. In certain arrangements, the firstframe piece 230 and the second frame piece 232 fit together, such as bysnap engagement.

As can be seen in FIG. 5, in the embodiment depicted, the frameconstruction 222 is molded or embedded within the polymeric end cap 202,along the inner annular region 244 of the ring 204.

The particular filter element 70 depicted further includes an innersupport liner 246 and an outer support liner 248. Each of the innerliner 246 and outer liner 248 extends between the first end 196 andsecond end 198 of the media pack 190. The inner liner 246 and outerliner 248 help to support the media 194. The liners 246 and 248, intypical arrangements, are constructed of a plastic, porous structurethat permits gas flow therethrough. The outer liner 248 circumscribesthe media 194 and the region of fibrous media 224.

It is noted that alternate materials can be used for the liners. Also insome instances the outer liner, the inner liner or both, are notrequired, depending on the structural integrity of the filter media 194.

In the particular embodiment illustrated in FIG. 5, the inner liner 246is an integral, unitary part of the second frame piece 232. That is, theinner liner 246 and the second frame piece 232 are a single member. Theinner liner 246 also forms a drain surface 250 for allowing the drippageand flow of coalesced liquid from the first stage coalescer filter 64down to the bowl 150.

The filter element 70 also includes an end cap 254 at the second end 198of the media pack 190. The end cap 254 preferably is constructed of amolded, polymeric material, such that the media 194 is potted orembedded there within. Similarly, the inner liner 246 and the outerliner 248, in certain preferred embodiments, extend between and areembedded within the molded, polymeric material of the first end cap 202and second end cap 254. The second end cap 254 includes an outer annularsurface 256 that forms a sealing portion 258. Typically, the sealingportion 258 is compressible, such that it is squeezed against thesealing surface 166 of the cover member 56 when the filter element 70 isoperably installed within the housing 52. The end cap 254 has anaperture 255 that, for the example shown, is aligned with the liquidflow outlet 62 to allow coalesced liquid to drain from the first stagecoalescer filter 64, through the aperture 255, and exit through theoutlet 62.

Attention is directed to FIG. 4. When the filter element 70 is operablyinstalled within the housing 52, the sealing portion 258 is compressedbetween and against the sealing surface 166 and the outer support liner248 to form a radial seal 260 therebetween. As can be also seen in FIG.4, the sealing portion 210 of the first end cap 202 is compressedbetween and against the sealing surface 128 and the outer support liner248 to form radial seal 214 therebetween. The radial seals 214, 260provide for the primary sealing system within the filter arrangement 50.The radial seals 214, 260 prevent unintended amounts of gas flow tobypass either one or both of the first stage coalescer filter 64 andsecond stage polishing filter 66.

Attention is again directed to FIG. 5. The sealing portion 258 of theend cap 254 also preferably includes a stepped construction 262. Thestepped construction 262 is analogous to the stepped construction 212 ofend cap 202. In the particular embodiment illustrated, there are threesteps of decreasing diameter, including step 264, step 266, and step268. Again, the stepped construction 262 helps in insertion of thefilter element 70 in the housing 52 and the formation of radial seal260.

The end cap 254 shown comprises a molded, polymeric material, such asmolded polyurethane foam having an as-molded density of typically lessthan 22 lbs per cubic foot, for example, about 10-22 lbs. per cubicfoot. One example material is described further below. Alternatematerials can be used.

Note that when the end caps 202 and 254 are molded in place, the endcaps 202, 254; the first and second plastic extensions 246, 248; themedia pack 190; and the non-pleated, non-woven fibrous media 24 aresecured together in the form of unitary, cylindrical filter element 70.

An alternative embodiment of filter element 70 is illustrated in FIG. 8at reference numeral 270. Element 270 is analogous to the element 70 ofFIG. 5, in that it includes end cap 272, end cap 274, an optional regionof fibrous media 276, media 278, and an outer liner 280. End cap 272includes a central gas stream inlet aperture 272 a. The element 270further includes an inner support liner 282 potted within, and extendingbetween the end caps 272, 274. In this embodiment, there is furtherincluded a flow construction 284 to aid in draining liquid that has beencoalesced by the optional fibrous media 276.

In the embodiment illustrated in FIG. 8, the flow construction 284includes a tube 286. In typical arrangements, the tube 286 extends fromthe downstream flow face 288 of the coalescer media 276 to the aperture290 of the end cap 274. The length of the tube 286 can vary betweenabout 33%-95% of the total length of the media 278. In many cases, thetube 286 with have a length of at least 25% of the media pack 190; andusually less than 100% of the length of the media pack 190. In typicalembodiments, the tube 286 will have at least a section 287 that isconstructed of a generally gas impermeable material, such that gas flowis required to exit from the downstream flow face 288, through the tubeinterior 292, past the end tip 294 of the tube 286, and then up into thevolume 296 before flowing through the media pack 190. The volume 296 isthe region between the inner liner 282 and the tube 286. In theparticular embodiment depicted, the entire tube 286 includes theimperforate section 287. In other embodiments, there may be portions ofthe tube 286 that are perforated, or gas permeable.

In the embodiment depicted, the tube 286 is part of a frame construction298 that is used to trap, encapsulate, or hold the optional fibrousmedia 276. Typically, the frame construction 298 will be molded withinthe end cap 272.

The tube 286 will aid in the drainage of coalesced liquid (typicallyoil). In operation, the coalesced liquid will drain by gravity along theinside wall 300 of the tube 286, and then drip into the bowl 150, andthen exit through the liquid flow outlet 62. The tube 286 can help toprevent coalesced liquid from being drawn into the media 278.

Another alternative embodiment of filter element 70 is illustrated inFIG. 9 at reference numeral 320. Element 320 is analogous to the element70 of FIG. 5, in that it includes end cap 322, end cap 324, an optionalregion of fibrous media 326, a media pack 327 (illustrated as media328), an outer liner 330, an inner liner 332, and a frame construction334 encapsulating the fibrous media 326. End cap 322 includes a centralgas stream inlet aperture 322 a. The media pack 327 defines an opentubular interior 333. The element 320 further includes an imperviousouter wrap 340 circumscribing and in covering relation to the outerliner 330.

In the embodiment depicted, the outer wrap 340 extends between about25-75% of the length of the media pack 327, typically from the end cap322 (holding the fibrous media 326) toward the other end cap 324(stopping short of the end cap 324). The outer wrap 340 aids in drainingliquid that has been coalesced by the optional fibrous media 326, asexplained further. In particular, the outer wrap 340 helps to preventgas flow through the region 342 of media 328 that is masked by the wrap340. This encourages gas flow to travel further in the direction towardthe end cap 324, and to the region 344 of media 326 that is not maskedby the wrap 340. This helps in the drainage by gravity of coalescedliquid out of the element 320.

A. Example Operation and Chance Out

In operation, the filter arrangement 50 works as follows. Blow-by gasesfrom an engine crankcase are taken in through the gas flow inlet port58. The gases pass into the interior 84 of the regulator valve housing74. The valve assembly 92 permits passage of the gas through the gap 106between the diaphragm construction 94 and the neck 88. The gap 106become larger as the pressure from the engine crankcase increases,causing the diaphragm construction 94 to move against the spring 96 andinto the volume 108 against the lid 57. The gas then flows into theinterior portion 104 of the neck 88. From there, it passes through theoptional first stage coalescer filter 64. The optional first stagecoalescer filter 64, when used, is secured within the construction suchthat the gas is directed through the first stage coalescer filter 64before the gas is directed through the media pack 190.

In particular the gas flow passes through the support grid 234 and intothe layer 228 of fibrous media 224. The gas continues to flow downstreamand through the layer 226, and then through the support grid 238. Thefibrous media 224 helps pre-separate liquids, with any entrained solids,from the rest of the gas stream. The liquid flows out of the media 224and either drips directly into the bowl 150, or drains along the drainsurface 250 of the inner liner 246. The collected liquid flows along thesloped wall 176 and ultimately through the liquid flow outlet 62. Thisliquid material often is oil, and may be recycled to the crankcase to bereused.

The gas stream, and any liquid that is not coalesced by the optionalfirst stage coalescer filter 64 continues on to the filter 66.Specifically, the gas flow travels from the open filter interior 192through the media pack 190. The gas flow is prevented from bypassingthis media due to the radial seals 214, 260. The media pack 190 removesselected additional liquid particles (by coalescing/drain) and selectedsolids from the gas stream. In the orientation shown in FIG. 4, themedia 194 is vertically oriented, such that any further liquid thatcollects (coalesces or agglomerates) on the media and falls or drain bygravity downwardly toward the bowl 150. The filtered gas then exitsthrough the gas flow outlet port 60. From there, the gases may bedirected, for example, to the turbo 34 intake of engine 30 or elsewhere(as described). In general, from outlet port 60 gases can in someinstances be vented to the atmosphere. Another instance is preferredthat the gas circulation be closed, and thus the gases are circulated toan air intake or elsewhere. For the particular example described in theprevious paragraph, the gases were described as potentially directed tothe turbo intake.

It should be noted that secondary seals 120, 174 prevent unintendedamounts of collected liquid, such as oil, from seeping between thefilter element 70 and the housing 52.

The filter arrangement 50 is serviced as follows. The cover member 56 isremoved from the body assembly 54 by releasing the latches 136. Thispermits the cover member 56 to be removed from the body assembly 54.When the cover member 56 is removed from the body assembly 54, the seal164 between the body 55 and cover member 56 is released. Further, theseal 260 between the filter element 70 and the cover member 56 isreleased. This also provides access to the filter element 70, whichincludes the optional first stage coalescer filter 64 and the tubularconstruction of media 66. The end of the filter element 70 adjacent tothe end cap 254 is grasped, and the filter element 70 is pulled in anaxial direction from the interior 112 of the body 55. As the filterelement 70 is pulled from the interior 112, the radial seal 214 isreleased. This step removes simultaneously both the first stagecoalescer filter 64 and the second stage polishing filter 66. Thisfilter element 70 may then be disposed of, such as by incineration.

A second, new, replacement filter element 70 is then provided. Thereplacement element 70 also includes the first stage coalescer filter 64and the second stage polishing filter 66 in an analogous construction asthe initial filter element 70. The replacement element 70 including boththe first stage 64 and second stage 66 is inserted through the open end144 of the body 55. The filter element 70 is oriented such that thesealing portion 210 of the end cap 202 is compressed between and againstthe sealing surface 128 and the outer liner 248 to form radial seal 214therebetween. In some embodiments, the filter element 70 is alsooriented such that the end cap 202 engages and abuts the end wall 114 ofthe body 55. Next, the cover member 56 is placed over the end of thefilter element 70 and oriented such that the sealing portion 258 of theend cap 254 is compressed between and against the outer liner 248 andthe sealing surface 166 of the cover member 56. This creates the radialseal 260. In some arrangements, the filter element 70 is also orientedsuch that the end cap 254 axially engages and abuts the stop 170 of thecover member 56.

With both seals 214 and 260 in place, the cover member 56 is then lockedto the body assembly 54 by engaging the latches 136. This also helps tocreate the seal 164 between the cover member 56 and body 55.

B. Example Constructions and Systems

The filter arrangement 36 is useful on a 1.5 liter-16 liter engine,50-1200 hp, turbo charged, or super charged, diesel, or natural gas. Inone application, the engine is a 250-400 hp, V-8 engine. The engine hasa piston displacement of at least 3 liters, typically 7-14 liters. Ittypically has 8-16 cfm of blow-by gases generated. Preferred filterarrangements 36 can handle blow-by gases from 1-20 cfm.

In other systems, the filter arrangement 36 is useful on engines withthe following powers: 8 kw-450 kw (11-600 hp); 450-900 kw (600-1200 hp);and greater than 900 kw (>1200 hp). In general, as the power of theengine increases, the second stage media 194 will be increased insurface area. For example, for engine powers 8 kw-450 kw (11-600 hp),when pleated media is used, the length of the pleats will be about 4-5inches; for engine powers 450-900 kw (600-1200 hp), the length of thepleats will be about 6-8 inches; and for engine powers greater than 900kw (>1200 hp), there will typically be more than one filter arrangement36 utilized.

It will be understood that a wide variety of specific configurations andapplications are feasible, using techniques described herein. Thefollowing dimensions are typical examples:

At least No greater Typical Structure (in.) than (in.) (in.) outerdiameter of element 70 2 12 4-5 inner diameter of element 70 0.5 101.5-2.5 length of element 70 3 12 4-6 diameter of media 224 0.5 10 2-2.5 thickness of each layer 226, 228 0.05 1 0.1-0.3 diameter of inlet58 0.5 3  1-1.5 diameter of gas flow outlet 60 0.5 3  1-1.5 diameter ofneck 88 0.5 3  1-1.5 height of projection 116 0.01 0.25 0.05-0.1 diameter of open end 144 3 14 4.5-5.5 diameter of lid 57 3 14 4.5-5.5diameter of diaphragm 96 3 14 4.5-5  diameter of inner wall 156 3 134.5-5  diameter of outer wall 154 3 14  5-5.5 diameter of liquid flowoutlet 62 0.05 2 0.1-0.5 height of projection 172 0.01 0.25 0.05-0.1 length of housing 52 4 15 7-8

C. Example Materials

In this section, certain example materials useful for the embodiment ofFIGS. 2-7 are described. A variety of materials may be used, other thanthose described herein.

The housing 50 can be plastic, such as carbon filled nylon.

The media 224 of the optional coalescer 64 is generally non-pleated,non-cylindrical, polyester fibrous media having an average fiberdiameter of less than about 18 microns, typically about 12.5 microns anda percent solidity, free state, of no greater than about 1.05%. Themedia 224 has an upstream, and a downstream exposed surface area of atleast 1 in.², no greater than about 7 in.², and typically about 3-4 in.²The material has an average fiber diameter of 1.5 denier (about 12.5micron), and a solidity in a free state of at least 0.85%. It has aweight of, typically, greater than about 3.1 ounces per square yard.Typically, it has a weight less than 3.8 ounces per square yard. Typicalweights are within the range of 3.1-3.8 ounces per square yard (105-129grams per square meter). Typically, the media has a thickness at 0.002psi compression (free thickness) of greater than about 0.32 inches.Typically, the media has a thickness at 0.002 psi compression (freethickness) of less than about 0.42 inches. Typical free thicknesses forthe media are in the range of 0.32-0.42 inches (8.1-10.7 millimeters).The media has a typical permeability of no less than about 370 feet perminute (113 meters per minute).

It is noted that the media 224 of the optional coalescer 64 could beprovided by a preferred bi-component fiber containing media, in generalas described in detail herein below, in section VI.

The end caps 202, 254 can be a polymeric material. In some examples, theend caps 202, 254 is urethane, and more particularly, foamedpolyurethane. One example foamed polyurethane is described in commonlyassigned U.S. Pat. No. 5,669,949 for end cap 3, herein incorporated byreference. The material can be the following polyurethane, processed toan end product (soft urethane foam) having an “as molded” density of10-22 pounds per cubic foot (lbs/ft³) and which exhibits a softness suchthat a 25% deflection requires about a 10 psi pressure. In someembodiments, the “as molded” density varies from the 10-22 lbs/ft³range. The polyurethane comprises a material made with 135453R resin andI305OU isocyanate. The materials should be mixed in a mix ratio of 100parts 135453 resin to 36.2 parts I3050U isocyanate (by weight). Thespecific gravity of the resin is 1.04 (8.7 lbs/gallon) and for theisocyanate it is 1.20 (10 lbs/gallon). The materials are typically mixedwith a high dynamic shear mixer. The component temperatures should be70-95° F. The mold temperatures should be 115-135° F.

The resin material I35453R has the following description:

(a) Average molecular weight

-   -   1) Base polyether polyol=500-15,000    -   2) Diols=60-10,000    -   3) Triols=500-15,000

(b) Average functionality

-   -   1) total system=1.5-3.2

(c) Hydroxyl number

-   -   1) total systems=100-300

(d) Catalysts

-   -   1) amine=Air Products 0.1-3.0 PPH    -   2) tin=Witco 0.01-0.5 PPH

(e) Surfactants

-   -   1) total system=0.1-2.0 PPH

(f) Water

-   -   1) total system=0.03-3.0 PPH

(g) Pigments/dyes

-   -   1) total system=1-5% carbon black

(h) Blowing agent

-   -   1) 0.1-6.0% HFC 134A.

The I3050U isocyanate description is as follows:

(a) NCO content—22.4-23.4 wt %

(b) Viscosity, cps at 25° C.=600-800

(c) Density=1.21 g/cm³ at 25° C.

(d) Initial boiling pt.—190° C. at 5 mm Hg

(e) Vapor pressure=0.0002 Hg at 25° C.

(f) Appearance—colorless liquid

(g) Flash point (Densky-Martins closed cup)=200° C.

The materials I35453R and I3050U are available from BASF Corporation,Wyandotte, Mich. 48192.

The frame construction 222, inner liner 246, outer liner 248, andscreens 234, 238 can be constructed of plastic, such as carbon fillednylon.

When pleated media is used the filter 66 is preferably constructed of anoleo-phobic material. One example is synthetic glass fiber filtermedium, coated and corrugated to enhance performance in ambient air-oilmist conditions. When pleated, the media 194 has a face velocity of atleast 0.1 ft/min., no greater than 5 ft/min., and typically about0.3-0.6 ft./min. The pleat depth is no less than 0.5 in., no greaterthan 3 in., and typically about 0.75-2 in. The pleat length is at least1 in., no greater than 15 in., and typically 3-6 in. The pleated media194 has an upstream media surface area of at least 2 ft² and preferablyabout 3-5 ft². There are at least 30 pleats, no greater than about 150pleats, and typically about 60-100 pleats. The synthetic glass fiberfilter media may be coated with a low surface energy material, such asan aliphatic fluorocarbon material, available from 3M of St. Paul, Minn.Prior to coating and corrugating, the media has a weight of at least 80pounds/3000 sq. ft; no greater than about 88 pounds/3000 sq. ft;typically in a range from about 80-88 pounds/3000 square feet (136.8±6.5grams per square meter). When pleated, the media has a thickness of0.027±0.004 inches (0.69±0.10 millimeters); a pore size of about 41-53microns; a resin content of about 21-27%; a burst strength, wet off themachine of 13-23 psi (124±34 kPa); a burst strength wet after 5 minutesat 300° F. of 37±12 psi (255±83 kPa); a burst strength ratio of about0.30-0.60; and a permeability of 33±6 feet per minute (10.1±1.8 metersper minute). When pleated, after corrugating and coating, the media hasthe following properties: corrugation depth of about 0.023-0.027 inches(0.58-0.69 millimeters); a wet tensile strength of about 6-10 pounds perinch (3.6±0.91 kilograms per inch); and a dry burst strength aftercorrugating of no less than 30 psi (207 kPa).

When pleated media is used for the filter 66, the ratio of the upstreamsurface area of the coalescer media 224 to the upstream surface area ofthe pleated media 194 is less than 25%, typically less than 10%, and insome instances, less than 1%. The ratio of the downstream surface areaof the coalescer media 224 to the upstream surface area of the pleatedmedia 194 is less than 25%, typically less than 10%, and in someinstances, less than 1%.

In many typical arrangements according to the present disclosure, filter66 will not be provided in a pleated form and will not comprise thematerials characterized above. Rather preferred fibrous material asdescribed herein below in Section VI will be used.

The housing 52 may be constructed of a molded plastic, such as glassfilled nylon. The diaphragm construction 94 can be constructed of adeflectable material, such as rubber.

III. The Embodiments of FIGS. 10-15

Another alternative embodiment of a coalescer filter and gas cleanerarrangement is depicted in FIGS. 10-12 at 400. The gas cleaner filterarrangement 400 includes a housing 402. The depicted housing 402 has atwo-piece construction. More specifically, housing 402 comprises a bodyassembly 404 and a removable cover member 406. The body assembly 404includes body 405 and lid 407.

Housing 402 includes the following four ports: gas flow inlet port 405;gas flow outlet port 410; port 412; and gas flow bypass outlet port 414.In general, and in reference now to FIG. 12, the gas cleaner filterarrangement 400 includes optional first stage coalescer filter 416 andsecond stage filter media 418. In use in the arrangement shown, the port412 acts as a liquid flow outlet port or liquid drain 412. In thearrangement shown, a liquid entrained gas stream is directed through thegas flow inlet port 408 and then through the optional first stagecoalescer filter 416. A portion of the liquid phase would be coalescedand removed from the gaseous stream by the optional first stagecoalescer filter 416. The liquid that is coalesced within the optionalfirst stage coalescer filter 416 drains and exits the housing 402through the liquid flow outlet port 412. The gas phase is directed froma flow passageway 423 and the optional first stage coalescer 416 throughthe filter media 418. The media construction 418 provides furthercoalescing/drainage of liquid particles removes at least a portion ofsolid particulates from the gas stream, and the cleaned gas stream isthen directed outwardly from the housing 402 through the gas flow outletport 410.

As with the embodiment depicted in FIG. 5, the optional first stagecoalescer filter 416 and the media 418 are a single, unitaryconstruction forming a filter arrangement or element 420 (FIGS. 13-15).In typical designs, the filter element 420 is removable and replaceablefrom the housing 402. As with the embodiment of FIG. 5, “unitary” meansthat the optional first stage coalescer filter 416 and second stagemedia 418 cannot be separated without destroying a portion of theelement 420. In typical embodiments, the first and second end caps 444,445 are part of the unitary construction.

In reference again to FIGS. 10 and 12, for the body assembly 404depicted, there is an inlet tube construction 422, a valve housing 424,a canister portion 426, and an outlet tube construction 428. In theembodiment shown, each of the inlet tube construction 422, valve housing424, canister portion 426, and outlet tube construction 428 comprise aportion of the body 405. Together with the lid 407, the body 405 and thelid 407 are part of the body assembly 404. The lid 407, in theembodiment depicted, is secured to the body 405 through selectivelyremovable mechanical engagement, such as a bolt arrangement 409. Thebolt arrangement 409 provides selective access to a regulator valveassembly 496.

The filter element 420 is constructed and arranged to be removablymountable within the housing 402. That is, the filter element 420 andthe housing 402 are designed such that the housing 402 can beselectively opened in order to access the filter element 420. The filterelement 420 is designed to be selectively mountable and removable fromwithin an interior 403 of the housing 402. When the filter element 420is oriented as shown in FIG. 12, with all of the seals (to be describedbelow) in place, the filter element 420 is considered to be operablyinstalled within the housing 402.

As mentioned above, the housing 402 is designed to be selectivelyopenable in order to access the filter element 420. In the particularembodiment illustrated, the cover member 406 is secured to the body 405through a latch arrangement 429. The latch arrangement 429 preferablyselectively holds the cover member 406 tightly and securely to andagainst the body 405, when the latch arrangement 429 is in a lockedstate. In the one depicted, the latch arrangement 429 includes at leasttwo latches 433, and in this embodiment, first and second wire latches433.

In reference to FIG. 12, note that the body 405 and cover member 406include a seal arrangement 421. In particular, note that the cover 406includes a pair of opposing flanges 413, 415 defining a receiving slot417 therebetween. The body 405 includes a flange 411 that fits in theslot 417. Typical such embodiments also include an O-ring seal member419 seated within the slot 417.

FIG. 15 depicts the filter element 420 as it would appear in anuninstalled state, that is, when it is not mounted within the housing402. FIG. 13 shows an end view of the filter element 420, while FIG. 14shows an opposite end view of the filter element 420. In general, filterelement 420 includes regions 431, 432 of filter media. In the filterelement 420 depicted in the drawings, the filter media 431 includes atubular extension 434 that defines a tubular open filter interior 436.In certain constructions, the tubular extension of media 434 isconfigured to have a generally cylindrical shape, defining a tubular(for example circular, although alternatives are possible)cross-section. The region of media 431 can be many types of media 438.However, it preferably includes non-pleated media as described inSection VI. The region of media 431, when installed in the filterarrangement 400, preferably acts to provide selected coalescing/drainageof liquid particles and selected removal of solid particulates beforethe gas stream leaves housing 402.

In the illustrated embodiment, the media 438 has a first end 440 and anopposite second end 441. The length of the media 438, in typicalembodiments, extends between the first end 440 and the second end 441.In the filter element 420 shown, at the first end 440, is a first endcap arrangement 442. In the particular one shown, the first end caparrangement 442 includes an end cap 444 and an optional rigid,pre-formed insert 446 molded therein. In such constructions, the firstend cap arrangement 442 can be a single, unitary structure. As will bedescribed further below, the pre-formed insert 446 includes a frameconstruction 450, which holds the optional first stage coalescer filter416 in operable assembly.

Still in reference to FIG. 15, at the second end 441 of the media 438,is a second end cap arrangement 443. The second end cap arrangement 443includes at least a second end cap 445.

As mentioned above, the filter element 420 includes at least the secondand first regions of media 431, 432. In the arrangement, the secondregion of media 431 can be pleated media, and/or it can be a wrapped orformed media. Preferably it is a media as described in Section VI below.The optional first region of media 432, is oriented in extension acrossthe tubular extension 434 of the second region of media 431 to be in gasflow communication with the open filter interior 436. By the phrase“oriented in extension across the tubular extension”, it is meant thatthe optional first region of media 432 does not radially overlap thesecond region of media 431 to itself form a tubular extension; rather,the optional first region of media 432 extends across and covers the endcap aperture 445. The optional first region of media 432 may be itselfembedded within the end cap 444 or be oriented adjacent to but spacedfrom the end cap 444 in a direction toward the end cap 445. The optionalfirst region of media 432 is not necessarily contained within a singleplane, but in typical embodiments, the optional first region of media432 is a non-tubular, non-cylindrical, generally panel construction 448.By “panel construction” it is meant that the first region of media 432permits gas flow to maintain a generally straight path therethrough.That is, the gas flow is not required to turn a corner as it flows froman upstream face 452 to a downstream face 454.

In some embodiments, and in reference to FIG. 15A, the optional firstregion of media 432 also corresponds to the first stage coalescer filter416. In typical embodiments, the optional first region of media 432includes fibrous media 456, although it could comprise a preferred mediaas described in Section VI. In certain embodiments, the media 456includes at least one layer, and typically, a plurality of layers 458 ofa fibrous bundle of non-woven, non-pleated, non-open tubular, coalescingdepth media 459. In the embodiments shown in FIGS. 12 and 15, there aretwo layers 461, 462 of fibrous depth media 459. Useable materials forthe fibrous media 456 are described above in connection with media 224of FIG. 5.

Attention is directed to FIG. 13, where the first end cap 444 is shownin plan view. In some embodiments, the end cap 444 includes a ring 466of a molded, polymeric material. The ring 466 defines a center aperture468 that, in the embodiment illustrated, is centered in the ring 466. Inother words, the aperture 468 has a center of symmetry that is the sameas the center of symmetry of the ring 466. In the particular embodimentillustrated, the center aperture 468 is circular. The aperture 468functions as a gas stream inlet aperture. The aperture 468 is shownaligned (either overlapping or coaxial with) the flow passageway 423 ofthe first stage coalescer filter 416.

The end cap 444 includes an axial portion 470 and an annular or radialportion 472. The aperture 468 provides for gas flow communication withthe open filter interior 436. The axial portion 470 of the end cap 444includes at least one continuous projection 474. In some embodiments,the continuous projection 474 helps to form a secondary seal 476 (FIG.12) with the housing 402, when the filter element 420 is operablyinstalled within the housing interior 403. In the particular embodimentillustrated in FIG. 13, the continuous projection 474 forms a circularring 478.

The radial portion 472 of the end cap 444 forms an annular sealingportion 480. When the filter element 420 is operably assembled withinthe housing 402, the annular sealing portion 480 forms a seal member482. In the embodiment shown in FIG. 13, the seal member 482 is alongthe inner annular surface of the ring 466, to circumscribe the aperture468.

When the filter element 420 is operably installed within the housing402, the seal member 482 forms a seal 484 (in this instance a radialseal) with the housing 402. In particular, in the arrangement shown inFIG. 12, the body 405 of the housing 402 includes an internal tube 486.The tube 486 includes a rigid wall 488 that circumscribes and defines agas flow aperture 490. When constructed as shown in FIG. 12, the wall488 has a sealing portion 492 that is designed to extend through theaperture 468 of the end cap 444 and into the open filter interior 436.The wall 488 also has an end portion 494 that may, in certain instances,interact with valve assembly 496. The valve assembly 496, its operation,and its interaction with the wall 488 are discussed in further detailbelow.

In FIG. 12, it can be seen that the radial seal 484 is formed againstthe sealing portion 492 of the tube 486. In some embodiments, the radialseal 484 is formed by compression of the material of the first end cap444 between and against the sealing portion 492 of the tube 486 and thepre-formed insert 446 embedded within the end cap 444. In this context,by “between and against” it is meant that the material of the first endcap 444 extends transversely the distance between the sealing portion492 of the tube 486 and the pre-formed insert 446, and is compressed indimension due to the rigidity of portion 492 and insert 446.

In reference now to FIG. 15A, the annular sealing portion 480, in theparticular embodiment illustrated, includes a stepped construction 498,although alternatives are possible. The stepped construction 498 helpswith the insertion and formation of the radial seal 484 between the endcap arrangement 442 and the sealing portion 492 of the housing 402. Inthe embodiment illustrated, the stepped construction 498 includes aplurality of regions of decreasing diameters, extending from the axialportion 470 of end cap 444 to the upstream face 452 of the fibrous media456. In FIG. 15A, the stepped construction 498 includes a first regionof largest diameter 501, adjacent to a second region 502 of a diametersmaller than the first region 501, adjacent to a third region 503 of adiameter smaller than that of the second region 502, adjacent to afourth region 504 smaller than that of the third region 503. Thisstepped construction 498 of decreasing diameters results in sealingportion 480 that helps with the insertion of the filter element 420 intothe housing 402 and the formation of the radial seal 484.

The sealing portion 480 of the end cap 444 is, for example, made from acompressible material, such that there is radial compression of thesealing portion 480 against the sealing portion 492 of the tube 486 ofthe housing 402. In some examples, end caps 444 comprise a soft,polyurethane foam having an as-molded density of about 10-22 pounds percubic foot. One usable material is described above in connection withthe sealing portion 410; another usable material is described furtherbelow.

Referring again to FIG. 12, the filter arrangement 400 shown includes aflow construction arrangement 510 oriented to direct fluid, such ascoalesced liquid, from the optional first region of media 432 toward theliquid flow outlet 412. In general, the flow construction arrangement510 includes a tube 512 formed by a section 513 of impervious,continuous, uninterrupted wall 514 surrounding and defining an open,fluid passage 516. In certain embodiments, the tube 512 extends from thedownstream face 454 of the first stage coalescer filter 416 at leastpartially in a direction toward the second end cap 445. In someembodiments, the tube 512 extends a complete distance between thedownstream face 454 and the second end cap 445. In the particulararrangement depicted, the tube 512 forms an aperture 520, preferably afluid exit aperture 523, at the end 521 of the wall 514 adjacent to thesecond end cap 445. In this manner, in this particular arrangement,liquid that is coalesced by the first stage coalescer filter 416 isallowed to collect along the interior 517 of the tube 512 and drip bygravity to the liquid flow outlet port 412. Alternate drain arrangementsare also usable. While in the depicted embodiment, the entire wall 514includes the imperforate section 513, in other embodiments, onlyportions of the wall 514 will be imperforate.

In the embodiment of FIG. 8, the flow construction arrangement 284 wasdepicted in the drawing as being generally straight, and unangled. Inthe embodiment of FIGS. 12 and 15, the flow construction arrangement 510is depicted as a conical section 515 having a sloped or tapered wall514. In certain constructions, the angle of taper on the wall 514 willbe adjusted depending upon the overall length of the element 420. Thatis, in some constructions, the size of the aperture 468 generallyremains fixed. As the length of the media 438 becomes greater, thelength of the overall element 420 becomes greater, and the angle ortaper of the wall 514 decreases. In certain arrangements, the angle oftaper, as measured from a longitudinal axis 518 (FIG. 15) passingthrough the symmetrical center of the element 420, is at least 1°extending from end 519 (adjacent to the coalescer filter 416) to end521. In some arrangements, the angle of taper can be 2-15°, andtypically less than 45°. The taper or angle on the wall 514 helps todirect the coalesced liquid in the direction of the fluid exit aperture520 and ultimately through the liquid flow outlet port 412.

After passing through the first stage coalescer filter 416, the gasflows through the fluid passageway 516, out through exit aperture 520,and then into a gas flow plenum 522. The gas flow plenum 522 is formedbetween the wall 514 of the tube 512 and the media 438. The taper on thewall 514 causes the gas flow plenum 522 to be angled between a volume524 adjacent to the second end cap 445 and a volume 526 adjacent to thefirst end cap 444 that is smaller than volume 524.

In reference now to FIG. 14, the depicted second end cap 445 includes aring 506 defining a center aperture 507. The aperture 507 allows for thepassage of liquid collected by the optional first stage coalescer filter416 to exit the filter element 420, in the particular system depicted inFIG. 12. The end cap 445 supports a sealing arrangement 508 for forminga seal 509 (FIG. 12) with the housing 402. In the embodiment illustratedin FIG. 12, the particular seal 509 depicted is an axial seal 530 formedbetween the filter element 420 and an inner sealing surface 531 of thecover member 406. In some embodiments, the sealing arrangement 508includes a projection 534 extending or projecting in an axial directionfrom a generally flat, planar portion 536 of the second end cap 445. Incertain embodiments, the projection 534 forms a continuous ring 538.Some constructions include the end cap 445 and the projection 534 as asingle, unitary, molded construction 540. In some embodiments, the endcap construction 540 is made from a polymeric material, preferably, acompressible polymeric material such as polyurethane. In someembodiments, the second end cap 445 is made from the same material asthe first end cap 444. The axial seal 530 helps to prevent gas from theinlet port 408 from bypassing the first stage coalescer filter 416 andthe second stage construction of filter media 418. The axial seal 530also helps to prevent the seepage of liquid such as oil from passing tothe downstream side of the second stage filter media 418.

As mentioned above, the first end cap arrangement 442 includespre-formed insert 446. In the embodiment depicted in FIGS. 12 and 15,the pre-formed insert 446 includes frame construction 450 for holdingand encapsulating the fibrous media 456. The frame construction 450 isnow further described. In reference to FIG. 15, the particular frameconstruction 450 depicted is a multi-piece construction 546. In theembodiment shown in FIG. 15A, the multi-piece construction 546 includesat least a first frame piece 550 and a second frame piece 552. The firstframe piece 550 includes a support grid 554 in covering relation to theupstream flow face 452 of the fibrous media 456. In certain examples,the support grid 554 is a porous, mesh screen 555 (FIG. 13) that permitsgas flow, including gas entrained with liquid, to flow therethrough andacross the coalescer media 456. The screen 555 also provides structuralsupport to the fibrous media 456.

Similarly, the second frame piece 552 includes a support grid 556supporting and in covering relation to the downstream flow face 454 ofthe fibrous media 456. The support grid 556 shown includes a porous,mesh screen 557 (FIG. 14) and provides structural support for thefibrous media 456 while permitting gas and coalesced liquid to passtherethrough and into the fluid passageway 516 of the flow constructionarrangement 510.

In the arrangement shown, the first frame piece 550 and the second framepiece 552 are oriented adjacent to each other to form a retaining pocket560 between the screen 555 and the screen 557 to form a housing 562 thatholds or encapsulates the fibrous media 456. In some embodiments, thefirst frame piece 550 and the second frame piece 552 mechanicallyengage, for example, through interlock structure such as a snapengagement 564.

In some embodiments, the pre-formed insert 446 forming the frameconstruction 450 is molded or embedded within the polymeric end cap 444along an inner annular region 566 of ring 568. Ring 568, in theembodiment depicted in FIGS. 12 and 15, is integral with and the samepiece as the second frame piece 552. The ring 568 generally comprises asurrounding wall 570 in projection or extending from screen 555 to thefirst axial end 440 of the media 438. As can be seen in FIG. 15A, thewall 570 forms a rigid backstop to the compression of the end capmaterial in the sealing portion 480. That is, in preferredconstructions, the radial seal 484 is formed by compression of thesealing portion 480 between and against the backstop 572 and the sealingportion 492 of the wall 488.

As also can be appreciated from reviewing FIGS. 12, 15 and 15A, someembodiments include the tube 512 of the flow construction arrangement510 as an integral, unitary part of the second frame piece 552. As such,in the embodiment illustrated in FIGS. 12 and 15, the particular secondframe piece 552 shown, extends from the end 440, which forms thebackstop 472, along the length of the media 438, to the end 521 formingthe exit aperture 520.

Still in reference to FIGS. 12 and 15, some frame constructions alsoinclude a support ring or frame 574. The support frame 574 helps tocenter the frame construction 450 and to hold the frame construction 450evenly within the open filter interior 436. The support frame 574 can bea variety of arrangements and constructions that provide for structuralrigidity between the tube 512 and an inner perimeter 576 of the media438. In the particular one depicted in FIGS. 12, 14 and 15, the supportframe 574 includes a ring construction 578. The ring construction 578depicted mechanically engages the wall 514 adjacent to the end 521, suchas by a snap engagement 582. The ring construction 578 depicted includesat least an inner ring 584, which engages the wall 514, and an outerring 586, which may touch or be close to the inner perimeter 576 of thesecond stage tubular construction of filter media 418. The inner ring584 and outer ring 586 define a plurality of gas flow apertures 588therebetween, separated by a plurality of spokes or ribs 590. The ribs590 provide for structural support and integrity of the ringconstruction 578. The gas flow apertures 588 allow for the passage ofgas from the first stage coalescer filter 416 to the second stage filtermedia 418. That is, after the gas flow has passed through the firststage coalescer filter 416 and through the fluid passage 516, it flowsthrough the fluid exit aperture 520, turns a corner (about 180°) aroundthe end 521 of the wall 514 and flows through the plural apertures 588into the gas flow plenum 522. From there, the gas flows through thetubular extension of media 434.

In certain embodiments, the filter element 420 will also include anouter support 592, such as a liner 594. In some arrangements, thesupport 592 will extend between the first and second end caps 444, 445,and help to hold or provide support to the media 438. In someembodiments, the liner 594 includes expanded metal. In certainarrangements, the liner 594, as well as the other parts of the element420, will be non-metallic (at least 98% non-metallic, and preferably100% non-metallic material). In some embodiments, instead of a liner594, the media 438 will include a support band or roving. In still otherarrangements, support to the media (inner and/or outer) can be avoided,if the media has sufficient structural integrity.

As mentioned above, preferred filter arrangements 400 include valveassembly 496. In the embodiment illustrated in FIG. 12, the valveassembly 496 provides both a regulator valve function and a bypass valvefunction. The regulator valve function is first described. The valvehousing 424 includes an outer surrounding wall 601 defining an openinterior 603, where the gas to be treated, which flows from the enginecrank case through the inlet port 408, is allowed to flow and collectbefore passing into the filter element 420. In the illustrated valveassembly 496, there is a diaphragm 602 and a biasing mechanism, such asspring 605. In certain embodiments, the diaphragm 602 is generallycircular that is held by and rests upon a shelf 608. The shelf 608 issupported between the lid 407 and valve housing 424. Note that in theembodiment illustrated, there is a gap 610 between the diaphragm 602 andthe end portion 494 of the tube 486. The gap 610 allows for gas flowfrom the interior 603 of the valve housing 424 and into the gas flowaperture 490 of the tube 486. During operation, the spring 605 and thediaphragm 602 regulate flow into the tube 486.

The valve construction 496 also includes a bypass valve function. As themedia in the filter element 420 becomes occluded and restrictionincreases to an unacceptably high level, pressures within the interior603 of the valve housing 424 increase. This applies pressure against thediaphragm 602 and against the spring 604, until the gas is allowed toflow into an interior volume 612 defined by the lid 407. The gas thenflows through the gas flow bypass outlet port 414 (FIG. 10).

Example Operation and Service

In operation, the depicted filter arrangement 400 works as follows.Blow-by gases from an engine crankcase are taken in through the gas flowinlet port 408. The gases pass into the interior 603 of the valvehousing 424. The valve assembly 496 permits passage of the gas and intothe gas flow aperture 490. From there, the gas passes through the firststage coalescer filter 416.

The gas flow passes through the upstream face 452, through the optionalfibrous media 456, and out through the downstream face 454. The optionalfibrous media 456 separates a portion of liquids from the rest of thegas stream. The collected liquids flow out of the media 456 and, in thedepicted embodiment, either drips directly into the liquid flow outletport 412, or drains along the wall 514 of the flow constructionarrangement 510. After passing through the liquid flow outlet port 412,the liquid, which is often oil, may be directed back into the crankcasefor reuse.

The gas stream including liquid particles not coalesced and drained bythe optional first stage coalescer filter 416 flows through the fluidpassage 516, through the exit aperture 520, around the end 521 of thewall 514 (making about a 180° turn) and into the gas flow plenum 522.From the gas flow plenum 522, the gas flows through the filter media418, which selectively removes by coalescing/drainage additional liquidparticles and also selectively removes solid particles from the gasstream. The gas flow is prevented from bypassing the second stage media418 due to the radial seal 484 and axial seals 530, 476. The cleaned gasthen flows downstream from the second stage filter media 418 out throughthe gas flow outlet port 410. From there, the gases may be directed tothe turbo of the engine.

The filter arrangement 400 is serviced as follows. The cover member 406is removed from the body assembly 404 by disengaging the latches 433.When the cover member 406 is removed from the body assembly 404, theaxial seal 530 is released. The filter element 420 is exposed,projecting out of the body 405. The filter element 420 can then begrasped and pulled from the body 405. This releases the radial seal 484.Removing the filter element 420, of course, removes both the optionfirst stage coalescer filter 416 and the media construction 418. Theentire filter element 420 may be disposed. In many embodiments, thefilter element 420 is constructed of at least 99% non-metallicmaterials, such that the filter element 420 is incineratable.

A second, new filter element 420 may than be installed. The new filterelement 420 is installed within the housing 402 by putting the element420 through the opening exposed by the removed cover member 406. Theaperture 468 of the end cap 444 is oriented around the inlet tube 486,and slid laterally relative to the body 405 until the radial seal 484 isin place. Often, this is also when the projection 474 axially abuts thebody interior 405 and forms an axial seal 476.

The cover 406 is than oriented over the exposed end of the filterelement 420. The latches 433 are engaged, to operably secure the covermember 406 to the body 405. This also axially compresses the cover 406against the element 420, and the axial seal 530 is formed.

IV. The Embodiment of FIGS. 16-21

An alternative embodiment of a pre-formed insert is shown in FIGS.16-20, generally at 650. The insert 650 is usable in the filter element420 in place of the insert 446. The insert 650 lends itself toconvenient manufacturing techniques.

The insert 650 shown includes a frame construction 652; a flowconstruction arrangement 654; and a support ring or frame 656. Theseparts function analogously to the frame construction 450, flowconstruction arrangement 510, and support frame 574 described inconnection with FIG. 15.

The flow construction arrangement 654 includes a tube 660 formed byuninterrupted wall 662 surrounding and defining an open, fluid passage664. The wall 662 includes a wall section 663 that is impervious. In thedepicted embodiment, the entire wall 662 includes impervious wallsection 663. In other embodiments, the wall 662 may include sectionsthat are permeable to fluid. The wall 662 has an interior surface 666,which permits coalesced liquid to slide and drip to a liquid outletport. The wall 662 defines an exit aperture 668, at an end 670 of thetube 660. In many applications, the exit aperture 668 allows both gasand liquid to exit therethrough. For example, in preferred applications,the exit aperture 668 allows the collected liquid to exit the tube 660and flow into an appropriate liquid outlet port.

As with the embodiment of FIGS. 12 and 15, the wall 662, in somearrangements is a conical section 667, being sloped or tapered frominlet end 663 of the wall 662 to exit end 670. That is, in suchembodiments, when the tube 660 has a circular cross-section, thediameter at the inlet end 663 is larger than the diameter at the outletend 670. In some arrangements, the diameter at the inlet end 663 will beon the order of at least 0.5%, no greater than 25%, and typically 1-10%larger than the diameter at the end 670.

Still in reference to FIGS. 16 and 18, the frame construction 652 shownis provided for holding and encapsulating optional coalescing media 675.The frame construction 652 in this embodiment, is different from theframe construction 450 described above. In this particular embodiment,there is a first frame piece 681 and a second frame piece 682. The firstframe piece has a wall or an outer annular rim 684 defining an innervolume 685 (FIG. 19). Axially spanning across one end of the rim 681 andintegral with the wall 684 is a support grid 686, for example in theform of a porous, mesh screen 688. The screen 688 provides structuralsupport to the optional media 675 and permits gas flow to reach themedia 675.

The first frame piece 681 also includes an inner rim 690, spacedadjacent to the outer rim 684. The inner rim 690 helps to prevent theflow of polyurethane end cap material from blocking the upstream face692 of the media 675. (Example molding techniques, and the function ofthe rim 690, are described further below.) As can be seen in FIGS. 16and 17, the inner rim 690 is connected to the outer rim 684 with aplurality of ribs 694. The rim 690 is spaced, for example, no greaterthan 5 millimeters from the outer rim 684 to form end cap material (e.g.polyurethane) flow passages 691 therebetween.

The wall or rim 684 shown defines a recess 696 (FIG. 19) for engagingand receiving a mating detent 698. The detent 698 is part of the secondframe piece 682, in the particular embodiment illustrated. The detent698, recess 696 provides for convenient, quick assembly and permits thefirst and second frame pieces 681, 682 to be snapped together. Ofcourse, many other embodiments of mechanical engagement between thefirst and second frame pieces 681, 682 are contemplated.

The second frame piece 682 includes an annular wall 700 surrounding anddefining an open volume 702. In the particular embodiment illustrated,the wall 700 has a generally circular cross-section, which may beconstant (to form a cylinder) or somewhat tapered to conform to theoptional taper of the wall 662. The second frame piece wall 700 includesfirst and second opposite ends, 704, 706. In the embodiment illustrated,the end 704 generally corresponds to an inlet end 672.

Second frame piece 662 also includes a support grid 708 spanning theopen volume 702 and integral with the wall 700. The grid 708 showncomprises a screen 710. The screen 710 provides structural support tothe coalescing media 675 and engages and holds the downstream face 712of the optional media 675.

The first and second frame pieces 681, 682 form an interior volume orretaining pocket 714 to hold, entrap, and encapsulate the optionalcoalescing media 675. When used, the media 675 is typically mechanicallycompressed within the pocket 714, such that the grid 686 engages theupstream face 692 and the grid 708 engages the downstream face 712. Asdescribed above, the wall 700 includes a plurality of projections ordetents 678 extending or projecting internally into the volume 702 toengage or snap into the recess 696.

The second frame piece 682 also includes mechanical engagement structureto securably attach to the wall 662 of the tube 660. In particular, thesecond frame piece and the tube 660 also includes mechanical engagementstructure, such as a detent/recess engagement 718. In the particular wayshown in FIG. 19, the wall 700 includes a second plurality ofprojections 720 extending or projecting into the interior volume 702,while the wall 662 has a recess 722 sized to receive the detents orprojections 720. In this manner, the second frame piece 682 easily snapsand interlocks with the tube 660.

Still in reference to FIGS. 16 and 18, such frame constructions 652 canalso include support ring or frame 656. The support frame 656 isanalogous to the support frame 574, described above. As such, thesupport frame 656 helps to center the frame construction 652 and hold itevenly within an open filter interior. The support frame 656, in the onedepicted, includes a ring construction 725 having at least an inner ring(728) and an outer ring 730. The inner ring 728 and the outer ring 730are shown joined by a plurality of spokes or ribs 732. Between the innerrings 728 and outer ring 730, the ring construction 725 defines aplurality of gas flow passageways 734.

Attention is directed to FIG. 20. The ring construction 725 and the tube660 are constructed and arranged to permit convenient manufacturing andassembly. In particular, the ring construction 725 and the tube 660 areconfigured to be secured together, such as by a mechanical engagementarrangement 736. The mechanical engagement arrangement 736 is analogousto those detent/recess arrangements described above. In particular, theinner ring 728 includes a plurality of projections or detents 738extending radially internally of the ring 728. The wall 662 defines arecess 740 to accommodate the projections 738. In this manner, thesupport frame 656 can conveniently and mechanically engage or snap intoplace with structural integrity with the wall 662 of the tube 660.

The preformed insert 660 may be assembled as follows. The tube 660, thering construction 725, and the first and second frame pieces 681, 682are provided, for example through injection molding techniques. Theoptional media 675 is provided and includes more than one layer; asshown in FIG. 18, the media 675 is two layers 742, 743 of depth media.

The second frame piece 682 is oriented with respect to the tube 660,such that the opening 707 defined by the wall 700 at the second end 706is placed over an open end 663 of (FIG. 19) of the wall 662 of the tube660. The second frame piece 682 and the tube 660 are mechanicallysecured together through, for example, the mechanical engagement 718 ofthe projection 720 and recess 722. The two layers 742, 743 of media 675are oriented over the screen 710 of the second frame piece 682. Afterthe optional depth media 675 is placed within the volume or pocket 714,the first frame piece 681 is secured in position. In particular, theouter rim 684 is radially aligned with and inserted through the open end705 defined by the wall 700 at the first end 704. The first frame piece681 moves with respect to the second frame piece 682 along the interiorof the wall 700, until the first and second frame pieces 681, 682 aresecured together in mechanical engagement through the detent 698 andrecess 696 arrangement.

It should be noted that the first and second frame pieces 681, 682 canbe secured together with the optional fibrous bundle of media 675trapped therebetween before the second frame piece 682 is secured to thetube 660.

The ring construction 725 is secured to the tube 660 by sliding the end670 of the tube through the interior of the inner ring 728 and snappingthe pieces together through the mechanical engagement arrangement 736.Of course, the ring 725 and the tube 660 may be secured together at anypoint during the assembly process.

In some arrangements, the assembled pre-formed insert 650 may then besecured to the remaining portions of the filter element 420 through, forexample, molding techniques that are described further below.

In FIG. 21, a filter element 800 is shown in cross-section with theinsert 650 installed therein. It should be understood that, other thanthe insert 650, the filter element 800 is constructed identically to thefilter element 420. As such, the element 800 includes the optional firststage coalescer filter media 844, the filter media construction 846, afirst end cap 856, and an opposite, second end cap 858. Because theelement 800 includes the insert construction 650, it includes tube 660,media 675, first frame piece 681, second frame piece 682, ringconstruction 725, and two layers of depth media 742, 743, each asdescribed above.

Also as described above with respect to the filter element 420, the endcap 856 includes an inner, annular sealing portion 864, which forms aseal, for example a radial seal with portions of an inlet tube. The endcap 858 is also configured analogously to the end cap 445 of FIG. 15,including a projection 870, which forms a seal, for example an axialseal with a service cover. The media construction 846 includes media 878such as formed media or pleated media or other media extending betweenthe end caps 856, 858. The media 878 defines an open tubular interior879. The media 878 is preferably as characterized in Section VI.

V. Molding Techniques

Attention is now directed to FIGS. 22 and 23, which depict an examplemolding technique that is usable to manufacture filter elementsdescribed herein. In many arrangements, the insert construction (such aspreformed insert 446 and preformed insert 650) when used is assembled inadvance, according to techniques described above. The preformed insertdepicted in FIGS. 22 and 23 is shown generally at 900. The preformedinsert 900 includes a frame construction 902 for holding optionalcoalescer media 904. The preformed insert 900 also includes a tube ortapered wall 906 and a ring construction 908.

The media stage 909, such as media 910 is provided and formed in atubular form, in this instance, around the preformed insert 900. Themedia 910 with the insert 900 is oriented over a mold 912. Note that themold 912 includes a platform or mount 914. The frame construction 902rests upon the mount 914. Molten material for forming the end cap, suchas polyurethane foam, is poured into the mold 912 in the volume 916. Themolten end cap material 915 is formed in the negative shape of the mold912. The end cap material 915 rises as it cures and is allowed topenetrate the region 691 between, for example, the rim 690 and the outerrim 684 in the arrangement depicted in FIG. 17. This permits the end capmaterial 915 to secure the optional coalescer media 904 to the resultingend cap 918. The ends of the media 910 are also then secured to theresulting end cap 918 by being potted or molded into the end capmaterial 915. As can also be seen in FIG. 22, the backstop 920 of theframe construction 902 also becomes molded within the end cap 918. Ifdesired, an outer liner 922 is placed around the outer perimeter of thesecond stage media and is molded with the end cap material 915.

After the end cap 918 is formed, the assembly 924 is inverted and placedinto a mold 926. End cap material 928, such as polyurethane foam, restsin the volume 930. As the end cap material 928 cures, the ends of themedia 910 are molded and fixed in place in the end cap material 928 toend up being potted within a resulting end cap 932. Note that the ringconstruction 908 is oriented in a position spaced from the mold 926 andwith a mold plug 934 adjacent thereto, such that the ring construction908 does not become blocked with end cap material 928.

VI. General Media Formulations and Formation

Preferred crankcase ventilation filters of the type characterized hereininclude at least one media stage comprising wet laid media. The wet laidmedia is formed in a sheet form using wet laid processing, and is thenpositioned on/in the filter cartridge. Typically the wet laid mediasheet is at least used as a media stage stacked, wrapped or coiled,usually in multiple layers, for example in a tubular form, in aserviceable cartridge. In use, the serviceable cartridge would bepositioned with the media stage oriented for convenient drainagevertically. For example, if the media is in a tubular form, the mediawould typically be oriented with a central longitudinal axis extendinggenerally vertically.

As indicated, multiple layers, from multiple wrappings or coiling, canbe used. A gradient can be provided in a media stage, by first applyingone or more layers of wet laid media of first type and then applying oneor more layers of a media (typically a wet laid media) of a different,second, type. Typically when a gradient is provided, the gradientinvolves use of two media types which are selected for differences inefficiency. This is discussed further below.

Herein, it is important to distinguish between the definition of themedia sheet used to form the media stage, and the definitions of theoverall media stage itself. Herein the term “wet laid sheet,” “mediasheet” or variants thereof, is used to refer to the sheet material thatis used to form the media stage in a filter, as opposed to the overalldefinition of the total media stage in the filter. This will be apparentfrom certain of the following descriptions.

Secondly, it is important to understand that a media stage can beprimarily for coalescing/drainage, for both coalescing/drainage andparticulate filtration, or primarily for particulate filtration. Mediastages of the type of primary concern herein, are at least used forcoalescing/drainage, although they typically also have particulateremoval function and may comprise a portion of an overall media stagethat provides for both coalescing/drainage and desired efficiency ofsolid particulate removal.

In the example arrangement described above, an optional first stage anda second stage were described in the depicted arrangements. Wet laidmedia according to the present descriptions can be utilized in eitherstage. However typically the media would be utilized in a stage whichforms, in the arrangements shown, the tubular media stages. In someinstances when materials according to the present disclosure are used,the first stage of media, characterized as the optional first stagehereinabove in connection with the figures, can be avoided entirely, toadvantage.

The media composition of the wet laid sheets used to form a stage in aCCV (crankcase ventilation) filter for coalescing/drainage is typicallyas follows:

-   -   1. It is provided in a form having a calculated pore size (X-Y        direction) of at least 10 micron, usually at least 12 micron.        The pore size is typically no greater than 60 micron, for        example within the range of 12-50 micron, typically 15-45        micron.    -   2. It is formulated to have a DOP % efficiency (at 10.5 fpm for        0.3 micron particles), within the range of 3-18%, typically        5-15%.    -   3. It comprises at least 30% by weight, typically at least 40%        by weight, often at least 45% by weight and usually within the        range of 45-70% by weight, based on total weight of filter        material within the sheet, bi-component fiber material in accord        with the general description provided herein.    -   4. It comprises 30 to 70% (typically 30-55%), by weight, based        on total weight of fiber material within the sheet, of secondary        fiber material having average largest cross-sectional dimensions        (average diameters is round) of at least 1 micron, for example        within the range of 1 to 20 micron. In some instances it will be        8-15 micron. The average lengths are typically 1 to 20 mm, often        1-10 mm, as defined. This secondary fiber material can be a mix        of fibers. Typically polyester and/or glass fibers are used,        although alternatives are possible.    -   5. Typically and preferably the fiber sheet (and resulting media        stage) includes no added binder other than the binder material        contained within the bi-component fibers. If an added resin or        binder is present, preferably it is present at no more than        about 7% by weight of the total fiber weight, and more        preferably no more than 3% by weight of the total fiber weight.    -   6. Typically and preferably the wet laid media is made to a        basis weight of at least 20 lbs. per 3,000 square feet (9        kg/278.7 sq. m.), and typically not more than 120 lbs. per 3,000        square feet (54.5 kg/278.7 sq. m.). Usually it will be selected        within the range of 40-100 lbs. per 3,000 sq. ft. (18 kg-45.4        kg/278.7 sq. m).    -   7. Typically and preferably the wet laid media is made to a        Frazier permeability (feet per minute) of 40-500 feet per minute        (12-153 meters/min.), typically 100 feet per minute (30        meters/min.). For the basis weights on the order of about 40        lbs/3,000 square feet-100 lbs./3,000 square feet (18-45.4        kg/278.7 sq. meters), typical permeabilities would be about        200-400 feet per minute (60-120 meters/min.).    -   8. The thickness of the wet laid media sheet(s) used to later        form the described media stage in the crankcase ventilation        filter at 0.125 psi (8.6 millibars) will typically be at least        0.01 inches (0.25 mm) often on the order of about 0.018 inch to        0.06 inch (0.45-1.53 mm); typically 0.018-0.03 inch (0.45-0.76        mm).

Media in accord with the general definitions provided herein, includinga mix of bi-component fiber and other fiber, can be used as any mediastage in a crankcase ventilation filter as generally described above inconnection with the figures. Typically and preferably it will beutilized to form the tubular stage. When used in this manner, it willtypically be wrapped around a center core of the filter structure, inmultiple layers, for example often at least 20 layers, and typically20-70 layers, although alternatives are possible. Typically the totaldepth of the wrapping will be about 0.25-2 inches (6-51 mm), usually0.5-1.5 (12.7-38.1 mm) inches depending on the overall efficiencydesired. The overall efficiency can be calculated based upon the numberof layers and the efficiency of each layer. For example the efficiencyat 10.5 feet per minute (3.2 m/min) for 0.3 micron DOP particles formedia stage comprising two layers of wet laid media each having anefficiency of 12% would be 22.6%, i.e., 12%+0.12×88.

Typically enough media sheets would be used in the final media stage toprovide the media stage with overall efficiency measured in this way ofat least 85%, typically 90% or greater. In some instances it would bepreferred to have the efficiency at 95% or more. In the context the term“final media stage” refers to a stage resulting from wraps or coils ofthe sheet(s) of wet laid media.

A. The Preferred Calculated Pore Size

Many types of crankcase ventilation filters of the type of generalconcern to the present disclosure, typically have a tubular (cylindricalor otherwise) media stage having a height within the range of 101 to 305mm (4-12 inches).

This media performs two important functions:

-   -   1. It provides for some coalescing and drainage of oil particles        carried in the crankcase ventilation gases being filtered; and    -   2. It provides for selected filtration of other particulates in        the gas stream.

In general, if the pore size is too low:

-   -   a. Drainage of coalesced oil particles by gravity, downwardly        through (and from) the media, can be difficult or slowed, which        leads to an increase of re-entrainment of the oil into the gas        stream; and    -   b. Unacceptable levels of restriction are provided to the        crankcase gas flow through the media.

In general, if the porosity is too high:

-   -   a. Oil particles are less likely to collect and coalesce; and    -   b. A large number of layers, and thus media thickness, will be        necessary to achieve an acceptable overall level of efficiency        for the media pack.

It has been found that for crankcase ventilation filters, a calculatedpore size within the range of 12 to 50 micron is generally useful.Typically the pore size is within the range of 15 to 45 micron. Oftenthe portion of the media which first receives gas flow with entrainedliquid for designs characterized in the drawings, the portion adjacentthe inner surface of tubular media construction, through a depth of atleast 0.25 inch (6.4 mm), has an average pore size of at least 20microns. This is because in this region, a larger first percentage ofthe coalescing/drainage will occur. In outer layers, in which lesscoalescing drainage occur, a smaller pore size for more efficientfiltering of solid particles, may be desirable in some instances.

The term X-Y pore size and variants thereof when used herein, is meantto refer to the theoretical distance between fibers in a filtrationmedia. X-Y refers to the surface direction versus the Z direction whichis the media thickness. The calculation assumes that all the fibers inthe media are lined parallel to the surface of the media, equallyspaced, and ordered as a square when viewed in cross-sectionperpendicular to the length of the fibers. The X-Y pore size is adistance between the fiber surface on the opposite corners of thesquare. If the media is composed of fibers of various diameters, the d²mean of the fiber is used as the diameter. The d² mean is the squareroot of the average of the diameters squared.

It has been found that it is useful to have calculated pore sizes on thehigher end of the preferred range, typically 30 to 50 micron, when themedia stage at issue has a total vertical height, in the crankcaseventilation filter of less than 7 inches (178 mm); and, pore sizes onthe smaller end, about 15 to 30 micron, are sometimes useful when thefilter cartridge has a height on the larger end, typically 7-12 inches(178-305 mm). A reason for this is that taller filter stages provide fora higher liquid head, during coalescing, which can force coalescedliquid flow, under gravity, downwardly through smaller pores, duringdrainage. The smaller pores, of course, allow for higher efficiency andfewer layers.

Of course in a typical operation in which the same media stage is beingconstructed for use in a variety of filter sizes, typically for at leasta portion of the wet laid media used for the coalescing/drainage ininitial separation, an average pore size of about 30-50 microns will beuseful.

B. Solidity

Solidity is the volume fraction of media occupied by the fibers. It isthe ratio of the fibers volume per unit mass divided by the media'svolume per unit mass.

Typical wet laid materials preferred for use in media stages accordingto the present disclosure, especially as the tubular media stage inarrangements such as those described above in connection with thefigures, have a percent solidity at 0.125 psi (8.6 millibars) of under10%, and typically under 8%, for example 6-7%.

C. Thickness

The thickness of media utilized to make media packs according to thepresent disclosure, is typically measured using a dial comparator suchas an Ames #3W (BCA Melrose MA) equipped with a round pressure foot, onesquare inch. A total of 2 ounces (56.7 g) of weight is applied acrossthe pressure foot.

Typical wet laid media sheets useable to be wrapped or stacked to formmedia arrangements according to the present disclosure, have a thicknessof at least 0.01 inches (0.25 mm) at 0.125 psi (8.6 millibars), up toabout 0.06 inches (1.53 mm), again at 0.125 psi (8.6 millibars).Usually, the thickness will be 0.018-0.03 inch (0.44-0.76 mm) undersimilar conditions.

Compressibility is a comparison of two thickness measurements made usingthe dial comparator, with compressibility being the relative loss ofthickness from a 2 ounce (56.7 g) to a 9 ounce (255.2 g) total weight(0.125 psi-0.563 psi or 8.6 millibars-38.8 millibars). Typical wet laidmedia (at about 40 lbs/3,000 square feet (18 kg/278.7 sq. m) basisweight) useable in wrappings according to the present disclosure,exhibit a compressibility (percent change from 0.125 psi to 0.563 psi or8.6 millibars-38.8 millibars) of no greater than 20%, and typically12-16%.

D. Preferred DOP Efficiency at 10.5 ft/Minute for 0.3 Micron Particles

The preferred efficiency stated, is desirable for layers or sheets ofwet laid media to be used to generate crankcase ventilation filters.This requirement indicates that a number of layers of the wet laid mediawill typically be required, in order to generate an overall desirableefficiency for the media stage of typically at least 85% or often 90% orgreater, in some instances 95% or greater.

The reason a relatively low efficiency is provided in any given layer,is that it facilitates coalescing and drainage and overall function.

In general, DOP efficiency is a fractional efficiency of a 0.3 micronDOP particle (dioctyl phthalate) challenging the media at 10 fpm. A TSImodel 3160 Bench (TSI Incorporated, St. Paul, Minn.) can be used toevaluate this property. Model dispersed particles of DOP are sized andneutralized prior to challenging the media.

E. Physical Properties of the Wet Laid Media

Typical wet laid air filtration media accomplishes strength throughutilization of added binders. However this comprises the efficiency andpermeability, and increases solidity. Thus, as indicated above, the wetlaid media sheets and stages according to preferred definitions hereintypically include no added binders, or if binder is present it is at alevel of no greater than 7% of total fiber weight, typically no greaterthan 3% of total fiber weight.

Four strength properties generally define media gradings: stiffness,tensile, resistance to compression and tensile after fold. In general,utilization of bi-component fibers and avoidance of polymeric bindersleads to a lower stiffness with a given or similar resistance tocompression and also to good tensile and tensile after fold. Tensilestrength after folding is important, for media handling and preparationof filter cartridges of the type used in many crankcase ventilationfilters.

Machine direction tensile is the breaking strength of a thin strip ofmedia evaluated in the machine direction (MD). Reference is to Tappi494. Machine direction tensile after fold is conducted after folding asample 180° relative to the machine direction. Tensile is a function oftest conditions as follows: sample width, 1 inch (25.4 mm); samplelength, 4 inch gap (101.6 mm); fold—1 inch (25.4 mm) wide sample 180°over a 0.125 inch (3.2 mm) diameter rod, remove the rod and place a 10lb. weight (4.54 kg) on the sample for 5 minutes. Evaluate tensile; pullrate—2 inches/minute (50.8 mm/minute).

F. The Media Composition

1. The Bi-Component Fiber Constituent.

As indicated above, it is preferred that the fiber composition of themedia include 30 to 70%, by weight, of bi-component fiber material. Amajor advantage of using bi-component fibers in the media, is effectiveutilization of fiber size while maintaining a relatively low solidity.With the bi-component fibers, this can be achieved while stillaccomplishing a sufficiently high strength media for handlinginstallation in crankcase ventilation filters.

The bi-component fibers generally comprise two polymeric componentsformed together, as the fiber. Various combinations of polymers for thebi-component fiber may be useful, but it is important that the firstpolymer component melt at a temperature lower than the meltingtemperature of the second polymer component and typically below 205° C.Further, the bi-component fibers are integrally mixed and evenlydispersed with the other fibers, in forming the wet laid media. Meltingof the first polymer component of the bi-component fiber is necessary toallow the bi-component fibers to form a tacky skeletal structure, whichupon cooling, captures and binds many of the other fibers, as well asother bi-component fibers.

Although alternatives are possible, typically the bi-component fiberswill be formed in a sheath core form, with a sheath comprising the lowermelting point polymer and the core forming the higher melting point.

In the sheath-core structure, the low melting point (e.g., about 80 to205° C.) thermoplastic is typically extruded around a fiber of thehigher melting point material (e.g., about 120 to 260° C.). In use, thebi-component fibers typically have a average largest cross-sectionaldimension (average fiber diameter if round) of about 5 to 50 micrometeroften about 10 to 20 micrometer and typically in a fiber form generallyhave an average length of at least 1 mm, and not greater than 30 mm,usually no more than 20 mm, typically 1-10 mm. By “largest” in thiscontext, reference is meant to the thickest cross-section dimension ofthe fibers.

Such fibers can be made from a variety of thermoplastic materialsincluding polyolefins (such as polyethylenes, polypropylenes),polyesters (such as polyethylene terephthalate, polybutyleneterephthalate, PCT), nylons including nylon 6, nylon 6, 6, nylon 6, 12,etc. Any thermoplastic that can have an appropriate melting point can beused in the low melting component of the bi-component fiber while highermelting polymers can be used in the higher melting “core” portion of thefiber. The cross-sectional structure of such fibers can be a“side-by-side” or “sheath-core” structure or other structures thatprovide the same thermal bonding function. One could also use lobedfibers where the tips have lower melting point polymer. The value of thebi-component fiber is that the relatively low molecular weight resin canmelt under sheet, media, or filter forming conditions to act to bind thebi-component fiber, and other fibers present in the sheet, media, orfilter making material into a mechanically stable sheet, media, orfilter.

Typically, the polymers of the bi-component (core/shell or sheath andside-by-side) fibers are made up of different thermoplastic materials,such as for example, polyolefin/polyester (sheath/core) bi-componentfibers whereby the polyolefin, e.g. polyethylene sheath, melts at atemperature lower than the core, e.g. polyester. Typical thermoplasticpolymers include polyolefins, e.g. polyethylene, polypropylene,polybutylene, and copolymers thereof, polytetrafluoroethylene,polyesters, e.g. polyethylene terephthalate, polyvinyl acetate,polyvinyl chloride acetate, polyvinyl butyral, acrylic resins, e.g.polyacrylate, and polymethylacrylate, polymethylmethacrylate,polyamides, namely nylon, polyvinyl chloride, polyvinylidene chloride,polystyrene, polyvinyl alcohol, polyurethanes, cellulosic resins, namelycellulosic nitrate, cellulosic acetate, cellulosic acetate butyrate,ethyl cellulose, etc., copolymers of any of the above materials, e.g.ethylene-vinyl acetate copolymers, ethylene-acrylic acid copolymers,styrene-butadiene block copolymers, Kraton rubbers and the like.Particularly preferred in the present invention is a bi-component fiberknown as 271P available from DuPont. Others fibers include FIT 201,Kuraray N720 and the Nichimen 4080 and similar materials. All of thesedemonstrate the characteristics of cross-linking the sheath polymer uponcompletion of first melt. This is important for liquid applicationswhere the application temperature is typically above the sheath melttemperature. If the sheath does not fully crystallize then the sheathpolymer will remelt in application and coat or damage downstreamequipment and components.

An example of a useable bi-component fiber for forming wet laid mediasheets for use in CCV media is Dupont polyester bi-component 271P,typically cut to a length of about 6 mm.

2. The Secondary Fiber Materials.

The bi-component fibers provide a matrix for the crankcase ventilationfilter media. The additional fibers or secondary fibers, sufficientlyfill the matrix to provide the desirable properties for coalescing andefficiency.

The secondary fibers can be polymeric fibers, glass fibers, metalfibers, ceramic fibers or a mixture of any of these. Typically glassfibers, polymeric fibers or a mixture are used.

Glass fibers useable in filter media of the present invention includeglass types known by the designations: A, C, D, E, Zero Boron E, ECR,AR, R, S, S-2, N, and the like, and generally, any glass that can bemade into fibers either by drawing processes used for makingreinforcement fibers or spinning processes used for making thermalinsulation fibers.

Non-woven media of the invention can contain secondary fibers made froma number of both hydrophilic, hydrophobic, oleophilic, and oleophobicfibers. These fibers cooperate with the glass fiber and the bi-componentfiber to form a mechanically stable, but strong, permeable filtrationmedia that can withstand the mechanical stress of the passage of fluidmaterials and can maintain the loading of particulate during use.Secondary fibers are typically monocomponent fibers with average largestcross-sectional dimension (diameters if round) that can range from about0.1 on up, typically 1 micron or greater, often 8-15 microns and can bemade from a variety of materials including naturally occurring cotton,linen, wool, various cellulosic and proteinaceous natural fibers,synthetic fibers including rayon, acrylic, aramide, nylon, polyolefin,polyester fibers. One type of secondary fiber is a binder fiber thatcooperates with other components to bind the materials into a sheet.Another type of secondary fiber is a structural fiber that cooperateswith other components to increase the tensile and burst strength thematerials in dry and wet conditions. Additionally, the binder fiber caninclude fibers made from such polymers as polyvinyl chloride, polyvinylalcohol. Secondary fibers can also include inorganic fibers such ascarbon/graphite fiber, metal fiber, ceramic fiber and combinationsthereof.

The secondary thermoplastic fibers include, but are not limited to,polyester fibers, polyamide fibers, polypropylene fibers,copolyetherester fibers, polyethylene terephthalate fibers, polybutyleneterephthalate fibers, polyetherketoneketone (PEKK) fibers,polyetheretherketone (PEEK) fibers, liquid crystalline polymer (LCP)fibers, and mixtures thereof. Polyamide fibers include, but are notlimited to, nylon 6, 66, 11, 12, 612, and high temperature “nylons”(such as nylon 46) including cellulosic fibers, polyvinyl acetate,polyvinyl alcohol fibers (including various hydrolysis of polyvinylalcohol such as 88% hydrolyzed, 95% hydrolyzed, 98% hydrolyzed and 99.5%hydrolyzed polymers), cotton, viscose rayon, thermoplastic such aspolyester, polypropylene, polyethylene, etc., polyvinyl acetate,polylactic acid, and other common fiber types.

Mixtures of the fibers can be used, to obtain certain desiredefficiencies and other parameters.

The sheet media of the invention are typically made using papermakingprocesses. Such wet laid processes are particularly useful and many ofthe fiber components are designed for aqueous dispersion processing.However, the media of the invention can be made by air laid processesthat use similar components adapted for air laid processing. Themachines used in wet laid sheet making include hand laid sheetequipment, Fourdrinier papermaking machines, cylindrical papermakingmachines, inclined papermaking machines, combination papermakingmachines and other machines that can take a properly mixed paper, form alayer or layers of the furnish components, remove the fluid aqueouscomponents to form a wet sheet. A fiber slurry containing the materialsare typically mixed to form a relatively uniform fiber slurry. The fiberslurry is then subjected to a wet laid papermaking process. Once theslurry is formed into a wet laid sheet, the wet laid sheet can then bedried, cured or otherwise processed to form a dry permeable, but realsheet, media, or filter. For a commercial scale process, thebi-component mats of the invention are generally processed through theuse of papermaking-type machines such as commercially availableFourdrinier, wire cylinder, Stevens Former, Roto Former, Inver Former,Venti Former, and inclined Delta Former machines. Preferably, aninclined Delta Former machine is utilized. A bi-component mat of theinvention can be prepared by forming pulp and glass fiber slurries andcombining the slurries in mixing tanks, for example. The amount of waterused in the process may vary depending upon the size of the equipmentused. The furnish may be passed into a conventional head box where it isdewatered and deposited onto a moving wire screen where it is dewateredby suction or vacuum to form a non-woven bi-component web.

The binder in the bi-component fibers is activated by passing the mattthrough a heating step. The resulting material can then be collected ina large roll if desired.

3. Surface Treatments of the Fibers.

Modification of the surface characters of the fibers, increase in thecontact angle, can enhance drainage capability of filtration media andthus the formed elements of the filter (with respect to pressure dropand mass efficiency). A method of modifying the surface of the fibers isto apply a surface treatment such as a flouro chemical or siliconecontaining material, typically up to 5% by weight of the media.

The surface treatment agent can be applied during manufacture of thefibers, during manufacture of the media or after manufacture of themedia post-treatment, or after provision of the media pack. Numeroustreatment materials are available such as flourochemicals or siliconecontaining chemicals that increase contact angle. An example is theDuPont Zonyl™ flourochemicals, such as #8195.

In the following section, examples of materials are used.

4. Example Materials.

(a) Example A.

Example A is a sheet material useable for example, as a media phase in acrankcase ventilation filter, in which the media phase is required toprovide for both good coalescing/drainage and also which can be used inlayers to provide useable efficiencies of overall filtration. Thematerial will drain well and effectively, for example when used as atubular media construction having a height of 4 inches-12 inches(100-300.5 mm). The media can be provided in multiple wrappings, togenerate such a media pack.

Media example A comprises a wet laid sheet made from a fiber mix asfollows: 50% by wt. DuPont polyester bi-component 271P cut to 6 mmlength; 40% by wt. DuPont polyester 205 WSD, cut to 6 mm length; and 10%by wt. Owens Corning DS-9501-11W Advantex glass fibers, cut to 6 mm.

The DuPont 271P bi-component fiber is an average fiber diameter of about13 microns. The DuPont polyester 205 WSD fiber has an average fiberdiameter of about 12.4 microns. The Owens Corning DS-9501-11W has anaverage fiber diameter of about 11 microns.

The example A material was made to a basis weight of about 40.4lbs./3,000 sq. ft. The material had a thickness at 0.125 psi, of 0.027inches and at 0.563 psi of 0.023 inches. Thus, the total percent change(compressibility) from 0.125 to 0.563 psi, was only 14%. At 1.5 psi, thethickness of the material was 0.021 inches.

The solidity of the material at 0.125 psi was 6.7%. The permeability(frazier) was 392 feet per minute.

The MD fold tensile was 2.6 lbs./inch width. The calculated pore size,X-Y direction, was 43 microns. The DOP efficiency of 10.5 feet perminute per 0.43 micron particles, was 6%.

(b) Example B.

Example B was made from a fiber mixture comprising 50% by weight DuPontpolyester bi-component 271P cut to 6 mm length; and 50% by weight LauschB 50R microfiber glass. The microfiber glass had lengths on the order ofabout 3-6 mm. Again, the DuPont polyester bi-component 271P had anaverage diameter of 13 microns. The Lausch B 50R had an average diameterof 1.6 microns and a d² mean of 2.6 microns.

The sample was made to a basis weight of 38.3 lbs./3,000 square feet.The thickness of the media at 0.125 psi, 0.020 inches and at 0.563 psiwas 0.017 inches. Thus the percent changed from 0.125 psi to 0.563 psiwas 15%, i.e., 15% compressibility. At 1.5 psi, the sample had athickness of 0.016 inches.

The solidity of the material measured at 0.125 psi was 6.9%. Thepermeability of the material was about 204 feet/minute. The machinedirection fold tensile was measured at 3.9 lbs/inch width.

The calculated pore size X-Y direction was 18 microns. The DOPefficiency at 10.5 ft/minute for 0.3 micron particles, was 12%.

The Exhibit B material would be effective when used as a layer or aplurality of layers to polish filtering. Because of its higherefficiency, it can be used alone or in multiple layers to generate highefficiency in the media.

This material would be border line as a coalescer/drain material,however, due to the relatively small pore size.

The Exhibit B material, then, could be used to form a downstream portionof the media pack that included a media having a higher pore sizeupstream, to form a stage for coalescing/drainage.

In a tubular construction, for example, Exhibit A material could be usedto form an inside of the tube, with Exhibit B material used to form anoutside of the tube, the two together comprising a filtered media stagein a crankcase ventilation filter of desirable drain properties andoverall efficiency of filtering.

G. Crankcase Ventilation Filter Constructions Utilizing the PreferredMedia

The preferred wet laid media as characterized above in Section VI, andincluding in Sections VI. A-F, can be utilized in a variety of mannersin crankcase ventilation filter arrangements. In the arrangementsdescribed in the figures, they can be used for the tubular stage, forexample. Such media can also be used in the optional first stage, ifdesired.

Typically a tubular stage will be made using 20-70 wraps of coiled wetlaid media in accord with descriptions above. Of course alternatives arepossible.

Because of the good drain characteristics, in some instances it will bepossible to avoid the first stage, characterized herein as optional,when the tubular media stage comprises a media of the type characterizedherein. The reason is that such media can provide for initiallyefficient and effective coalescing and drainage, to be useable both aspart of the particulate filter stage and as the coalescing/drain stage.

As a result, the media characterized herein can offer a variety ofalternate configurations for crankcase ventilation filters. An examplewould be one in which the media is arranged in a tubular form, for flowtherethrough a crankcase ventilation gases. In others the media could beconfigured in panel arrangements or other arrangements.

In more general terms, a filtration system which manages bothcoalescing/drainage of our entrained liquid particulates, and alsofiltration of particles, should be designed to drain the collectedliquids rapidly, otherwise functional life of the filter media would beuneconomically short. The media is positioned so the liquid can drainfrom the media rapidly. Some key performance properties are: initial andequilibrium fractional efficiency, pressure drop and drainage ability.Some key physical properties of the media are thickness, solidity andstrength.

Generally the media for coalescing/drainage is aligned in a manner thatenhances the filters capability to drain. For tubular constructions,this would be a media position with the central axis of the tubeextending vertically. In this orientation, any given media compositionwill exhibit an equilibrium load height which is a function of the X-Ypore size, fiber orientation and the interaction of the liquid with thefiber surface, measured as contact angle. Collection of liquid in themedia will increase in height to a point balanced with the drainage rateof the liquid from the media. Of course any portion of the media that isplugged with draining liquid would not be available for filtration. Thussuch portions of the media would increase pressure drop and decreaseefficiency across the filter. As a result it is advantageous to controlthe portion of the element that remains with porous plugged by liquidphase. Alternately stated is it is advantageous to increase drainagerate.

The media factors effecting drainage rate are X-Y pore size, fiberorientation and interaction of the liquid being drained with the fibersurface. Reducing these to accomplish a desirable liquid flow is in partthe issue. The X-Y pore size being increased, facilitates drainage asexplained above. However this reduces the number of fibers forfiltration, thus the overall efficiency of the filter. To achieve targetefficiency, relatively thick media pack structure would be made, byusing multiple layers of material having a desirable X-Y pore size.Also, the fibers would preferably be oriented with a vertical directionof the media if possible, but this approach is generally difficult tomaximize. Typically the media, if provided in a tubular form, would beoriented with the X-Y plane from the wet laid manufacturing process,defining the surface of the tube and with the Z direction being thethickness.

The interaction of the liquid being drained with the surface of thefibers was discussed above. To enhance this, treatment supplied to thefiber surfaces can be used. Treatments discussed above areflourochemicals or silicone containing treatments. If a higherefficiency is desired than would be obtained with a media that isconstructed for good drainage, then at an upstream end of the media amore efficient media stage can be provided, typically as part of thesame media pack. This is discussed above, in the example providingExample A material as the earlier stage of the media pack in which mostcoalescing/drainage occurs, and the later material of Exhibit B toprovide for a higher efficiency polish.

H. Some General Observations

In general, the present disclosure relates to utilization of a media ofthe type characterized, within a coalescer/drain stage of a crankcaseventilation system; i.e., as a media stage in a crankcase ventilationfilter. The ventilation filter can have one media stage therein.

In some of the arrangements described, with respect to the drawings, thearrangements shown include an optional first stage and a tubular secondstage. The formed media can be used in either or both.

It is noted that because the first stage is characterized as optional,it will be understood that some crankcase ventilation filters can bemade which include only a media stage comprising a formed media ascharacterized herein. An example is shown in FIG. 24.

The reference numeral 2000, FIG. 24, generally indicates a crankcaseventilation cartridge including media 2001 as characterized herein. Themedia 2001 is positioned in extension between opposite end caps 2002 and2003. The cartridge 2000 will be provided with an appropriate sealarrangement for a housing, as needed. The particular seal arrangementfor cartridge 2000, is an outside radial seal on each of the end caps2002 and 2003, for example as shown in 2000 a, for end cap 2002.Alternative seals are possible including (for example): inside radialseals at each end cap; axial seal arrangement; combination of axial sealarrangements; and, housing seal arrangements which involve only one ofthe end caps, either axially or radially.

The media 2001 is shown schematically, and will comprise multiple wrapsof wet laid media in accord with the description herein. It couldinclude additional stages as well. Media stage 2001 is shown in atubular form.

Cartridge 2000 could be configured for either in-to-out flow orout-to-in flow. When configured for in-to-out flow, as will be typicalfor an arrangement as described in the other figures, the upstream edgeof the media 2001 would be at 2001 a and the downstream edge at 2001 b.

What is claimed is:
 1. A crankcase ventilation filter including: (a) a first, wet laid, media stage comprising: (i) at least 30% by weight, based on total weight of fiber material in the stage, bi-component fiber material having an average largest fiber cross-sectional dimension of at least 10 microns and average length of 1-20 mm, inclusive; and (ii) at least 30% by weight, based on total weight of fiber material in the stage, secondary fiber material intermixed with the bi-component fiber material, the secondary fiber material having an average largest fiber cross-sectional dimension of at least 1 micron and average length of 1 to 20 mm, inclusive; and (b) the first, wet laid, media stage having: (i) an added binder resin content, if any, of no greater than 7% by total weight of fiber material.
 2. A crankcase ventilation filter according to claim 1 wherein: (a) the wet laid media stage comprises a tubular media construction having a plurality of layers of wet laid fiber sheet and an overall media thickness of at least 6 mm.
 3. A crankcase ventilation filter according to claim 2 wherein: (a) the tubular media construction is positioned in extension between first and second end caps.
 4. A crankcase ventilation filter according to claim 1 wherein: (a) the first wet laid media stage has a fiber treatment therein selected from the group consisting essentially of silicone and fluorochemical fiber treatment materials.
 5. A crankcase ventilation filter according to claim 1 wherein: (a) the first wet laid media stage comprises 45 to 70%, by weight, of the bi-component fiber material; (b) 30 to 55%, by weight, of the secondary fiber material; and, (c) no more than 3%, by weight of total fiber content, added binder resin, if any.
 6. A crankcase ventilation filter according to claim 1 wherein: (a) a second media stage on a downstream side of the first, wet laid, media stage; (i) the second media stage having a different total efficiency than the first, wet laid, media stage.
 7. A crankcase ventilation arrangement according to claim 6 wherein: (a) the first wet laid media stage comprises a tubular media construction having a plurality of layers of wet laid fiber sheet and an overall media thickness of at least 12 mm.; and, (b) the second media stage is wrapped around the first, wet laid, media stage.
 8. A crankcase ventilation arrangement according to claim 7 wherein: (a) the second media stage is a second, wet laid, media stage comprising: (i) at least 30% by weight, based on total fiber weight in the stage bi-component fiber material having an average largest fiber cross-sectional dimension of at least 10 microns and an average length of 1-20 mm, inclusive; (ii) at least 30% by weight secondary fiber material having an average largest fiber cross-sectional dimension of at least 1 micron and average length of 1 to 20 mm, inclusive; (iii) calculated pore size, X-Y direction, of 12 to 50 microns, inclusive; and, (iv) an added binder resin content of no greater than 7% by total weight of fiber material.
 9. A crankcase ventilation filter according to claim 1 wherein: (a) the first, wet laid, media stage comprises 20 to 70 wraps of coiled wet laid media.
 10. A crankcase ventilation filter according to claim 1 wherein: (a) the bi-component fiber material has an average length of 1 to 10 mm; (b) the bi-component fiber material comprises polyester bi-component fiber material; and, (c) the secondary fiber material comprises fibers selected from glass fibers, polyester fibers, metal fibers and mixtures of two or more of glass fibers, polyester fibers and metal fibers.
 11. A crankcase ventilation filter according to claim 10 wherein: (a) the secondary fiber material is polyester fibers.
 12. A crankcase ventilation filtration assembly comprising: (a) a housing including a gas flow inlet arrangement, a gas flow outlet arrangement and a liquid drain outlet arrangement; and, (b) a serviceable crankcase ventilation filter operably positioned within the housing and comprising: (i) a first, wet laid, media stage comprising: (A) at least 30% by weight bi-component fiber material having an average largest fiber cross-sectional dimension of at least 10 microns and an average length of 1-20 mm, inclusive; (B) at least 30% by weight secondary fiber material intermixed with the bi-component fiber material, the secondary fiber material having an average largest fiber cross-sectional dimension of at least 1 micron and average length of 1 to 20 mm, inclusive; and (ii) the first, wet laid, media stage having (A) an added binder resin content of no greater than 7% by total weight of fiber material.
 13. A crankcase ventilation filtration assembly according to claim 12 wherein: (a) the first, wet laid, media stage is tubular; is positioned for in-to-out filtering flow; and, has a height of 101 to 305 mm.
 14. A crankcase ventilation filtration assembly according to claim 13 wherein: (a) the liquid drain outlet arrangement is configured for liquid flow through a portion of the gas flow inlet arrangement. 